Me8073 Ucmp MCQ PDF

Department of Mechanical Engineering MCQ for Regulations 2017
R2017
ME8073 - UNCONVENTIONAL MACHINING PROCESSES
Multi Choice Questions (MCQ)
UNIT I - INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES
[Syllabus]
[Unconventional machining Process – Need – classification – merits, demerits and

applications. Abrasive Jet Machining – Water Jet Machining – Abrasive Water Jet Machining
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- Ultrasonic Machining. (AJM, WJM, AWJM and USM). Working Principles – equipment used
– Process parameters – MRR- Applications.]
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Non Traditional Machining
C
1. Non-Traditional machining is recommended when we need which of the following
features?
T.
a) Complex shapes
b) High surface quality
c) Low-rigidity structures
O
d) All of the mentioned
Answer: d
SP
Explanation: For above requirements this machining is used.
2. Non-Traditional machining can also be called as ________

G
a) Contact Machining
b) Non-contact machining
LO
c) Partial contact machining

d) Half contact machining
Answer: b
Explanation: Tool and work piece are at a distance apart in this type of machining.
.B
3. In which of the following industries, Non-traditional machining methods play an important

role?
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a) Automobile
b) Aerospace
c) Medical
-R

Answer: d
Explanation: Non-traditional methods are used widely in many industries.
SE
4. Different classifications of Non-traditional machining based on source of energy are

________
a) Mechanical
C
b) Thermal
c) Chemical and electro-chemical.
Answer: d
Explanation: It can be classified into the above mentioned categories.
5. In mechanical machining, material is removed by ___________

a) Erosion
b) Corrosion
c) Abrasion
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d) Vaporization
Answer: a
Explanation: Abrasive grains remove material by mechanical erosion in USM.
6. Material in thermal machining is removed by which of the following means?

a) Vaporization
b) Melting
c) Electro-plating
Answer: d
Explanation: In this machining, heat is the source of energy.
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7. Which of the following process comes under mechanical machining?
a) USM
O
b) EDM
c) LBM
C
d) PAM
Answer: a
T.
Explanation: USM removes material by mechanical erosion.
O
8. Surface defects that may be occurred during thermal machining are ________
a) Micro cracking SP
b) Heat affected zones
c) Striations
Answer: d
G
Explanation: During thermal machining surfaces defects occur.
LO
9. Sources used in thermal machining are ________

a) Ions
b) Plasma
c) Electrons
.B

Answer: d
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Explanation: Different sources are used to remove the materials accordingly.
10. Vacuum is the machining medium for ________

a) LBM
-R
b) WJM
c) EBM
d) None of the mentioned
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Answer: a
Explanation: Vacuum is the medium for Laser Beam Machining and Ion Beam machining.
C
11. In chemical machining is material removal takes by?

a) Chemical reaction
b) Erosion
c) Electron removal
Answer: a
Explanation: Chemical machining removes material by chemical reactions.
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
Answer: c
Explanation: More than one phase is used to combine to form hybrid machining.
Water Jet Machining (WJM) – Introduction and machining system

13. What is the full form of WJM in advanced machining processes?
a) Water Jack Manufacturing
b) Water Jet Machining
c) Water Jet Manufacturing
d) Water Jack Manufacturing
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Answer: b
Explanation: The full form of WJM is water jet machining in advanced machining
processes.
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14. What is the key element of water jet machining for material removal?
C
a) Tool Holder
b) Work piece
T.
c) Water jet
d) Power source
O
Answer: c
Explanation: Water jet is the one, which is used to cut the work piece and to remove
material.
SP
15. What is the velocity of water jet stream in water jet machining?
a) 100 m/sec
G
b) 300 m/sec
c) 700 m/sec
LO
d) 900 m/sec
Answer: d
Explanation: Velocity of water jet stream that is used in Water jet machining is about 900
.B
m/sec.
16. Which of the following is not a part of machining system of Water jet machining?
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a) Transducer
b) Accumulator
c) Jet cutting nozzle
d) Hydraulic pump
-R
Answer: a
Explanation: Transducer is not a part of Water jet machining and other components come
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under WJM
17. What is the general power rating of the hydraulic pump, used in WJM?
a) 10 kW
C
b) 20 kW
c) 30 kW
d) 40 kW
Answer: c
Explanation: The power rating of the motor of hydraulic pump, which is used in WJM is
about 30 kW.
18. Which of the following are the components of intensifier present in water jet machining
system?
a) Piston

b) Plunger
c) Limit switch
Answer: d
Explanation: The above mentioned components are present in the intensifier of water jet
machining.
19. Intensifier increases the pressure water by which of the following values?
a) 10 – 100 MPa
b) 100 – 200 MPa
c) 200 – 400 MPa
d) 400 – 1000 MPa
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Answer: c
Explanation: Use of intensifier is to increase the inlet water pressure to 200 – 400 MPa.
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20. On which property of water, will the accumulator in Water jet machining rely on?
a) Density
C
b) Compressibility
c) Viscosity
T.
d) Velocity
Answer: b
O
Explanation: Accumulator relies on compressibility of water (12% at 3800bar), in order to
maintain a uniform discharge pressure in WJM.
SP
21. What are the values of typical tube diameters in the machining system in WJM?
a) 0.1 to 1 mm
b) 1 to 6 mm
c) 6 to 14 mm
G
d) 14 to 25 mm
Answer: c
LO
Explanation: Typical tube diameter values range between 6 to 14 mm.
22. What is the expected life of the nozzles used in WJM?

a) 10 hrs
.B
b) 20 hrs
c) 100 hrs
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d) 200 hrs
Answer: d
Explanation: The life that is expected from the nozzle, which is a part of machining
system, is 200 hrs.
-R
23. Which of the following does not damage the nozzle used in Water jet machining?
a) Particles of dirt
SE
b) Mineral deposits
c) Water
C
Answer: c
Explanation: Only dirt particles and mineral deposits are responsible for damage of
nozzle.
24. What are the uses of catcher in machining system of Water jet machining?
a) Collecting dirt
b) Collection of debris
c) Reduce noise levels

Answer: d
Explanation: Catcher in WJM is used to collect the dirt, machined debris and reduce the
noise levels.
WJM – Process Parameters and Material removal

25. Distance between which components, is the stand-off distance?
a) Nozzle-inlet and work piece top
b) Nozzle-outlet and work piece-top
c) Nozzle-inlet and work piece-bottom
d) Nozzle-outlet and work piece-bottom
Answer: b
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Explanation: Stand-off distance is the distance between top of work piece and
nozzle outlet.
O
26. What is the value of diameter of the jet cutting nozzle in WJM?
a) 0.01 – 0.1 mm
C
b) 0.1 – 0.3 mm
T.
c) 0.3 – 0.7 mm
d) 0.7 – 1.5 mm
Answer: b
O
Explanation: In WJM, diameter of the nozzles range between 0.10 – 0.30 mm.
SP
27. What is the value of stand-off distance in Water jet machining?
a) 0.1 – 1 mm
b) 1 – 2 mm
c) 2 – 6 mm
G
d) 6 – 14 mm
LO
Answer: c
Explanation: Stand-off distance value ranges between 2.5 – 6 mm in Water jet
machining.
.B
28. What are the values of jet velocities in Water jet machining?
a) 100 – 200 m/s
b) 200 – 500 m/s
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c) 500 – 1500 m/s

d) 1500 – 3000 m/s
Answer: c
-R
Explanation: Velocity of the water jet stream ranges between 540 – 1480 m/s in WJM.
29. State whether the following statement is true or false.

SE
“As the pump pressure increases, depth of cut decreases in Water jet machining.”
a) True
b) False
Answer: b
C
Explanation: As the pump pressure is increases, the depth of cut also increases in
WJM.
30. What is the value of material thickness of work piece in WJM?

a) 0.001 – 0.25 mm
b) 0.8 – 25 mm
c) 50 – 100 mm
d) 100 – 500 mm
Answer: b
Explanation: The material thickness value of work piece range between 0.8 – 25 mm.

31. What is the value of feed rate in Water Jet Machining?

a) 0.0001 – 0.025 m/min
b) 0.05 – 0.25 m/min
c) 0.5 – 200 m/min
d) 200 – 500 m/min
Answer: c
Explanation: In Water jet machining, value of the feed rate ranges between 0.5 – 200
m/min.
32. In WJM, what are the properties of jet fluid that affect the MRR?
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a) Velocity
b) Flow rate
c) Viscosity
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Answer: d
C
Explanation: All the mentioned properties above, of jet fluid affect the MRR in Water jet
machining.
T.
33. Which of the following property/ies of nozzle does not affect the material removal rate in
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Water jet machining?
a) Material SP
b) Diameter
c) Outside temperature
d) Stand-off distance
Answer: c
G
Explanation: In the nozzle, outside temperature has no effect on the rate of material
removal.
LO
WJM – Applications
34. In the following materials, Water jet machining can be used on which type of material?
.B
a) Metals
b) Plastics
c) Ceramics
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Answer: d
Explanation: WJM can be used on metals, cloth, paper, plastics, food, leather, and
-R
ceramics.
35. What are the processes and applications, where Water jet machining can be used?
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a) Cutting
b) Drilling
c) Deburring
C
Answer: d
Explanation: Water jet machining can be used for drilling, cutting, deburring, surface
treatment and many more applications.
36. What is the tolerance limit range of thin materials in WJM?

a) ± 0.1 mm
b) ± 10 mm
c) ± 25 mm
d) ± 50 mm

Answer: c
Explanation: In Water jet machining, the range of tolerance is ± 25 mm.
37. In cutting of rocks using water jet machining, which type of pressure is needed?
a) Low pressure
b) Medium pressure
c) High pressure
Answer: c
Explanation: In WJM, very high pressures and velocities are needed while cutting rocks.
M
38. In deburring, which combination removes the material from non-metallic materials?
a) High pressure and low flow rate
b) High pressure and high flow rate
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c) Low pressure and low flow rate
d) Low pressure and high flow rate
C
Answer: a
Explanation: For non-metallic materials high pressure and lower flow rates are used in
T.
deburring.
39. Which of the following materials has some drawbacks of cutting WJM?
O
a) Food
b) Rocks SP
c) Fibre-reinforced plastics
Answer: c
Explanation: Water gets deflected due to the fibre embedded in the matrix of fibre-
G
reinforced plastics when we use WJM.
LO
40. What is the accuracy level obtained when PCB’s are cut by WJM?
a) ± 0.05 mm
b) ± 0.13 mm
c) ± 0.26 mm
.B
d) ± 0.33 mm
Answer: b
Explanation: In WJM, accuracy obtained in cutting of PCB’s is ± 0.13 mm.
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41. In WJM, surface treatment includes which type of processes?

a) Removing deposits
-R
b) Removing chemicals
c) Degreasing
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Answer: d
Explanation: Surface treatment is done using WJM to clean the surface from many toxic
chemical, deposits, residues etc
C
WJM – Advantages and Disadvantages

42. In how many directions, can the cutting takes place in Water jet machining?
a) Uni-directional
b) Bi-directional
c) Multi-directional
Answer: c
Explanation: Water jet machining has multi directional cutting capacity i.e.., in any
direction in three dimensional space.

43. In Water jet machining, cuts can be started at which place of workpiece?
a) From left
b) From right
c) From middle
d) From any point
Answer: d
Explanation: In WJM, cuts can be started from any point on the workpiece.

“To start the cuts in Water jet machining, pre-drilled holes are not necessary.”
a) True
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b) False
Answer: b
Explanation: In Water jet machining, we need not require any pre-drilled holes to start
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the cuts.
C
45. Which of the following is not an advantage of Water jet machining?
a) Burr produced is minimal
T.
b) No Heat is produced
c) Relatively low hourly rates
O
d) Environmentally safe
Answer: c SP
Explanation: Costs per hour are relatively high in Water jet machining.
46. In Water jet machining, tool need not require sharpening once the machining is done.
a) True
G
b) False
Answer: a
LO
Explanation: Tool does not wear in water jet machining, so it need not be sharpened.
47. Which of the following secondary processes are eliminated in Water jet machining?
a) Grinding of surface
.B
b) Surface treatment
c) Polishing of surface
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Answer: d
Explanation: All the mentioned secondary processes above, are eliminated in Water jet
machining.
-R
48. How many parts are cut using Water jet machining, on a single blank?
a) One part
SE
b) Two parts
c) Three parts
d) Multiple parts
C
Answer: d
Explanation: Depending up on the kerf width, multiple parts can be machined using a
single blank.
49. Which of the following is the disadvantage of water jet machining?

a) Narrow kerf width
b) Small diameter of nozzle
c) Not suitable for mass production
d) Burr is minimal
Answer: c
Explanation: Due to high maintenance, WJM cannot be used for mass production.

Abrasive Jet Machining (AJM) – Introduction and Machining system

50. . In advanced machining processes, what is the full form of AJM?
a) Automatic Jet Manufacturing
b) Abrasive Jet Machining
c) Automated Jet Machining
d) Abrasive Jet Manufacturing
Answer: b
Explanation: In advanced machining processes, full form of AJM is Abrasive jet
machining.
M
51. In AJM, which of the following materials are used as abrasive grains?
a) Al2O3
O
b) SiC
c) Glass beads
C
Answer: d
T.
Explanation: In Abrasive jet machining, any of the particles mentioned above can be
used as abrasive grains.
O
52. In Abrasive jet machining, work piece material of removed by which of the following
means?
a) Vaporization
SP
b) Electro plating
c) Mechanical abrasion
d) Corrosion
G
Answer: c
Explanation: Abrasive particles hit the surface with high pressure and high velocities,
LO
which removes the material.
53. Which type of materials can be machined using Abrasive jet machining?
.B
a) Glass
b) Ceramics
c) Hard materials
17

Answer: d
Explanation: Materials like ceramics, glass, hard and super hard materials can be
-R
machined using Abrasive jet machining.
54. In machining system of AJM, which is the medium of carrying the abrasive grains for
SE
machining?
a) Liquids
b) Gases
c) Any fluids
C

Answer: b
Explanation: In AJM, different types of gases are used as the medium for carrying
abrasives.
55. In machining system of AJM, what is/are the gas/es used for carrying the abrasives?
a) CO2
b) Air
c) Nitrogen

Answer: d
Explanation: In AJM, gases like CO2, air or nitrogen are used to carry the abrasives.
56. What is the pressure of gas that is to be supplied, for carrying the abrasives?
a) 0.1 to 1.0 kg/cm2
b) 2.0 to 8.0 kg /cm2
c) 10.0 to 18.0 kg/cm2
d) 25.0 to 35.5 kg/cm2
Answer: b
Explanation: The pressure of the carrying gas should range between 2 to 8 kg/cm2.
M
57. Which of the following gas, should never be used as the carrier of abrasives?
a) Nitrogen
b) CO2
O
c) Oxygen
d) Air
C
Answer: c
Explanation: Oxygen should not be used as carrier because it causes a violent chemical
T.
reaction with abrasives or work piece.
O
58. What is the frequency of mixing chamber, consisting of gas and abrasives?
a) 10 Hz SP
b) 30 Hz
c) 50 Hz
d) 70 Hz
Answer: c
G
Explanation: Mixing chamber consisting of carrier gas and the abrasive grains, vibrates
at a frequency of 50 Hz.
LO
59. In Abrasive jet machining, what may be the size of the abrasive grains used?
a) 10 – 40 µm
b) 50 – 100 µm
.B
c) 100 – 150 µm
d) 200 – 300 µm
17
Answer: a
Explanation: Abrasive grains of size, between 10 – 40 µm can be used for machining.
60. What are the processes where Abrasive jet machining can be used?
a) Cleaning
-R
b) Cutting
c) Deburring
SE
Answer: d
Explanation: Abrasive jet machining can be used for deburring, cutting, cleaning and for
many other heavy duty applications.
C

“In Abrasive jet machining, commercial grades powders can be used for machining.”
a) True
b) False
Answer: b
Explanation: For AJM, commercial grade powders are not used because their sizes are
not classified widely.
62. In machining system of AJM, which of the following controls the relative motion between
work piece and nozzle?

a) Cam drives
b) Pantographs
c) Trace mechanisms
Answer: d
Explanation: Relative motion in Abrasive jet machining can be controlled by the above
mentioned means.
63. Masks, which are used to confine the jet stream location on work piece are made of,
which type of materials?
a) Copper
M
b) Glass
c) Rubber
O
Answer: d
Explanation: Masks can be made of any of the above-mentioned materials.
C
AJM – Material Removal Rate and Process parameters
T.
64. In AJM, what is the mechanism of removal of material from the work piece?
a) Corrosion
O
b) Abrasion
c) Electron transfer
d) Vaporization
SP
Answer: b
Explanation: In Abrasive jet machining, the removal of material takes places by
mechanical abrasion, using abrasive grains.
G
65. In AJM, abrasive jet from the nozzle follows, which type of path for a short distance?
LO
a) Parallel
b) Inclined
c) Perpendicular
.B

Answer: a
Explanation: Abrasive particles follow a parallel path for short distance and then flare
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outward.
66. Which of the following components, influence the material removal rate in Abrasive jet
-R
machining?
a) Nozzle
b) Carrier gas
SE
c) Abrasive grains
Answer: d
Explanation: All the components mentioned above, influence the rate of material removal,
C
directly or indirectly.
67. In the following properties of nozzle, which of them does not influence the MRR?
a) Size
b) Wear
c) Outside temperature
d) Distance from work piece
Answer: c
Explanation: The outside temperature of nozzle has no influence on the material removal
rate.

68. In the following properties of abrasive grains, which of them changes rate of material
removal?
a) Size
b) Strength
c) Shape
Answer: d
Explanation: The above mentioned properties of abrasive grains influence the material
removal rate.
M
69. As the abrasive flow rate increases, what happens to the volumetric removal rate?
a) Increases
b) Decreases
O
c) Increase and then decrease
d) Decrease and then increase
C
Answer: c
Explanation: In AJM, volumetric removal rate increases up to a level and then decreases.
T.
70. What is the value of abrasive grain flow rate in Abrasive jet machining?
a) 0.1 – 2 g/min
O
b) 3 – 20 g/min
c) 30 – 56 g/min
SP
d) 68 – 85 g/min
Answer: b
Explanation: Abrasive grain flow rate is between 3 – 20 g/min, in AJM.
G
71. What must be the velocity of the carrier gas that carries the abrasive particles?
LO
a) 10 – 50 m/sec
b) 50 – 150 m/sec
c) 150 –300 m/sec
d) 300 – 500 m/sec
.B
Answer: c
Explanation: Velocity of abrasive carrier gas must be between 150 – 300 m/sec.
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72. What is the value of carrier gas flow rate in Abrasive jet machining?
a) 6 L/min
b) 17 L/min
-R
c) 28 L/min
d) 39 L/min
Answer: c
SE
Explanation: In Abrasive jet machining, the flow rate of abrasive carrier gas is around 28
L/min.
C
73. Which of the following material/s cannot be used for making of nozzle in Abrasive jet
machining?
a) Tungsten Carbide
b) Steel alloy
c) Sapphire
d) Synthetic sapphire
Answer: b
Explanation: Nozzle in Abrasive jet machining is made up of sapphire or WC.
74. Which of the following values, does the diameter of the nozzle lies between?
a) 0.01 – 0.10 mm

b) 0.30 – 0.50 mm
c) 0.70 – 0.90 mm
d) 1.10 – 1.50 mm
Answer: b
Explanation: In AJM, Diameter of the nozzle ranges between 0.30 – 0.50 mm.
75. What is the life of Tungsten carbide material nozzle?

a) 1 – 8 hrs
b) 2 – 5 hrs
c) 10 – 15 hrs
d) 25 – 40 hrs
M
Answer: c
Explanation: Nozzle made up of WC material has a life period which range between 10 –
15 hrs.
O
76. In AJM, what is the life of synthetic sapphire material nozzle?
C
a) 100 hrs
b) 300 hrs
T.
c) 500 hrs
d) 700 hrs
O
Answer: b
Explanation: Nozzle made up of synthetic sapphire material has a life period which is
SP
about 300 hrs.
77. What are the tolerance limit values in Abrasive water jet machining?
a) ± 0.01 mm
G
b) ± 0.03 mm
c) ± 0.05 mm
LO
d) ± 0.07 mm
Answer: c
Explanation: In Abrasive jet machining, tolerance limit values range between ± 0.05 mm.
.B
78. In AJM, surface roughness value will vary between which values?
a) 0.01 – 0.10 µm
b) 0.15 – 1.5 µm
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c) 2.0 – 5.0 µm
d) 7.0 – 10.0 µm
Answer: b
-R
Explanation: Surface roughness value in AJM varies between 0.15 – 1.5 µm, depending
on grain size.
SE
AJM – Applications, Advantages and limitations

79. Which of the following, are the processes and applications in which Abrasive jet
machining can be applied?
C
a) Drilling
b) Cutting
c) Deburring
Answer: d
Explanation: Abrasive jet machining can be used for cutting, drilling, deburring and
cleaning processes.
80. Using abrasive jet machining, wire cleaning and insulation stripping take place without
affecting the conductor.

a) True
b) False
Answer: a
Explanation: Without affecting the conductor, both stripping and cleaning are done, by
using Abrasive jet machining.
81. In Abrasive jet machining, intricate shapes and holes are machined on which type of
materials?
a) Brittle
b) Thin
c) Difficult to machine
M
Answer: d
Explanation: Abrasive jet machining is used to machine, intricate shapes and holes in
O
brittle, thin and difficult to machine materials.
C
82. State whether the following statement is true or false, about Abrasive jet machining.
“Using Abrasive jet machining, micro deburring of hypodermic needles can take place.”
T.
a) True
b) False
O
Answer: a
Explanation: Abrasive jet machining can be used for micro deburring of hypodermic
SP
needles.
83. What are the type of materials that can be machined using Abrasive jet machining?
a) Glass
G
b) Sapphire
c) Quartz
LO

Answer: d
Explanation: In Abrasive jet machining, the above mentioned materials can be
machined, which are heat sensitive and brittle.
.B
84. What is the amount of material utilizes when we machine parts using Abrasive jet
17
machining?
a) Very low
b) Low
c) Medium
-R
d) High
Answer: d
Explanation: In Abrasive jet machining, material utilization is very high since it removes
SE
material by using abrasives.
85. After how much time tool has to be changed in AJM?

C
a) 1 hr
b) 2 hrs
c) 5 hrs
d) No tool change required
Answer: d
Explanation: In Abrasive jet machining, tool changes are not required.
86. By using Abrasive jet machining, how much amount of hardening does the materials
experience?
a) No hardening
b) Very less hardening

c) Average hardening
d) High hardening
Answer: a
Explanation: In Abrasive jet machining, hardening is not experienced by the machined
materials.
87. Which type of materials cannot be machined using Abrasive jet machining?
a) Soft materials
b) Hard materials
c) Difficult to machine materials
M
Answer: a
Explanation: Soft materials such as candy bars, thin softwood etc.., cannot be machined
using AJM.
O
88. Which of the following materials in Abrasive jet machining can be a health hazard?
C
a) Abrasive grains
b) Air carrier
T.
c) Silica dust
O
Answer: c
Explanation: Silica dust, that occurs after machining can be a health hazard in AJM.
SP
89. In AJM, air filters are used to remove which of the following?
a) Moisture
b) Oil
G
c) Other dust particles
LO
Answer: d
Explanation: Before machining, air has to be filtered to remove dust, moisture and oil in
the machining system.
.B
Abrasive Water Jet Machining (AWJM) – Introduction

90. In advanced machining processes, what is the full form of AWJM?
17
a) Automated Water Jet Machining

b) Automated Water Jet Manufacturing
c) Abrasive Water Jet Machining
d) Abrasive Water Jet Manufacturing
-R
Answer: c
Explanation: Full form of AWJM is Abrasive Water Jet Machining.
SE
91. What are all the types of materials, which can be machined using AWJM?
a) Glass
b) Ceramics
C
c) Concrete
Answer: d
Explanation: Hard to cut materials, which are mentioned above, can be machined using
Abrasive water jet machining.
92. When was Abrasive water jet machining developed first?

a) 1942
b) 1958
c) 1974
d) 1980

Answer: c
Explanation: Abrasive water jet machining was first developed in the year 1974.
93. When compared to the conventional machining, how much times faster, is the Abrasive
water jet machining?
a) 5 times
b) 10 times
c) 15 times
d) 20 times
Answer: b
M
Explanation: Abrasive water jet machining is 10 times faster than the conventional
machining.
O
94. What is the percentage of the abrasives and water in the mixture?
a) 20% water and 80% abrasives
C
b) 80% water and 20% abrasives
c) 30% water and 70% abrasives
T.
d) 70% water and 30% abrasives
O
Answer: d
Explanation: Abrasive mixture consists of 70 percent water and 30 percent abrasives.
SP
95. What are the materials used for abrasives in Abrasive water jet machining?
a) SiC
b) Corundum
G
c) Glass beads
LO
Answer: d
Explanation: All of the materials mentioned above can be used for making abrasives in
.B
Abrasive water jet machining.
96. In the machining system of AWJM, which one accelerates the abrasives to remove
17
material?
a) Water only
b) Water jet stream
c) Feeder
-R

SE
Answer: b
Explanation: Water jet stream accelerates abrasives but not the water only, to remove
material.
C
97. The introduction of compressed air to the water jet enhances the deburring action.
a) True
b) False
Answer: a
Explanation: Compressed air increases the pressure energy of the jet stream, which
enhances the material removal rate.
98. What is the grain size of abrasive particles, which are often used for Abrasive water jet
machining?

a) 0.01 – 0.50 µm
b) 10 – 150 µm
c) 200 – 500 µm
d) 500 – 1000 µm
Answer: b
Explanation: Grain size of the abrasive particles range between 10 – 150 µm in Abrasive
water jet machining.
99. How is the material removed in Abrasive water jet machining?

a) Vaporization
M
b) Electron transfer
c) Corrosion
d) Erosion
O
Answer: d
C
Explanation: In Abrasive water jet machining, material removal takes place by the erosion
of the work piece material using abrasives accelerated by jet stream.
T.
AWJM – Machining System
100. Which of the following is not the feed mechanism of the abrasives in AWJM?
O
a) Side feed
b) Cross feed
SP
c) Central feed
G
Answer: b
Explanation: Only side feed and central feed are used in Abrasive water jet machining.
LO
101. In Abrasive water jet machining, how are the abrasives fed into the water jet stream?
a) Suspension
.B
b) Injection
c) All of the mentioned
17
Answer: c
Explanation: Abrasives are fed into the water jet stream through suspension or injection.
-R
102. What is the use of delivery system in the machining system of AWJM?
a) To deliver colloidal solution
SE
b) To pump water
c) To fed abrasives
C
Answer: b
Explanation: In Abrasive water jet machining, water delivery system is used.
103. Of the following components, which one does not come under the machining system of
AWJM?
a) Water delivery system
b) Transducer
c) Cutting nozzles
d) Mixing chambers

Answer: b
Explanation: Transducer is the component which does not come under the machining
system of AWJM.
104. In Abrasive water jet machining, intensifier is used to deliver which type of pressure?
a) Very low pressure
b) Low pressure
c) Medium pressure
d) High pressure
Answer: d
M
Explanation: In AWJM, intensifier is used to deliver high pressure water using pistons with it.
105. In mixing chamber of AWJM, which of the following are mixed?
O
a) Abrasives and colloidal solution
b) Abrasives and water jet
C
c) Colloidal and water jet
T.
Answer: b
O
Explanation: In mixing chamber, abrasives and water jet stream are mixed.
SP
106. Of the following, which one is a type of suspension in AWJM?
a) Direct pumping
b) Indirect pumping
c) Bypass pumping
G
LO
Answer: d
Explanation: There are three different types of suspension AWJ formed by indirect, direct
and bypass pumping.
.B
107. In machining system of AWJM, mixing chamber is immediately followed by which of

the following component?
17
a) Focusing tube
b) Cutting Nozzle
c) Intensifier
d) Water delivery
-R
Answer: a
Explanation: In Abrasive water jet machining, mixing chamber is immediately followed by the
SE
focusing tube.
108. Which of the following energies are absorbed using the catchers in Abrasive water jet
C
machining?
a) Pressure energy
b) Kinetic energy of abrasives
c) Residual energy
Answer: c
Explanation: In AWJM, catchers are used to absorb the residual energy.
109. Which of the following are different types of catchers used in AWJM?
a) Water basin type

b) Submerged steel balls type

c) TiB2 type
Answer: d
Explanation: The above mentioned types are the types of catchers used in AWJM.
AWJM – Process Capabilities

110. Which of the following is not a process parameter of Abrasive water jet machining?
a) Frequency of vibration
b) Orifice diameter
M
c) Pressure
d) Stand-off distance
O
Answer: a
C
Explanation: Frequency of the vibrations does not belong to the parameters of Abrasive
water jet machining.
T.
111. Which of the following come under the process parameters of the Abrasive water jet
machining?
O
a) Abrasive size
b) Machine impact angle
SP
c) Traverse speed
G
Answer: d
Explanation: All the parameters mentioned above come under Abrasive water jet machining
LO
112. What is the value of orifice diameter in Abrasive water jet machining?
a) 0.01 – 0.03 mm
b) 0.03 – 0.09 mm
.B
c) 0.10 – 0.30 mm
d) 0.30 – 0.90 mm
17
Answer: c
Explanation: The value of diameter of the orifice should range between 0.10 – 0.30 mm.
-R
113. Of the following values, between which of them pressure value will range?
a) 1000 – 1500 bar
b) 1500 – 2500 bar
SE
c) 2500 – 4000 bar

d) 4000 – 10000 bar
Answer: c
C
Explanation: In Abrasive water jet machining, pressure value will range between 2500 –
4000 bar.
114. When compared to sand, how much effective is garnet as abrasive material in AWJM?
a) 20%
b) 30%
c) 40%
d) 50%

Answer: b
Explanation: Garnet, which is commonly used abrasive material is nearly 30% more effective
than sand in Abrasive water jet machining.
115. State whether the following statement is true or false about Abrasive water jet
machining.
“A material, whose material removal rate is higher, produces larger surface
roughness.”
a) True
b) False
M
Answer: a
Explanation: As rate of material removal increases in AWJM, large surface roughness are
produced.
O
116. Surface roughness depends on which of the following parameters in Abrasive water jet
C
machining?
a) Work piece material
T.
b) Grit size
c) Abrasive type
O
Answer: d
SP
Explanation: All the parameters mentioned above, are responsible for variation in surface
roughness.
G
117. What is the value of focusing diameter in Abrasive water jet machining?
a) 0.1 – 0.6 mm
LO
b) 0.8 – 1.4 mm
c) 1.6 – 2.8 mm
d) 3.2 – 5.2 mm
.B
Answer: b
Explanation: Diameter value of WC focusing tube in AWJM varies between 0.8 – 1.4 mm.
17
118. Abrasive flow value in Abrasive water jet machining will range between which of the
following values?
a) 0.01 – 0.1 kg/min
-R
b) 0.1 – 1.0 kg/min

c) 1.0 – 10 kg/min
d) 10 – 100 kg/min
SE
Answer: b
Explanation: In AWJM, abrasive flow ranges between 0.1 – 1.0 kg/min.
C
119. What is the value of stand-off distance in Abrasive water jet machining?
a) 1.0 – 2.0 mm
b) 2.0 – 4.0 mm
c) 4.0 – 6.0 mm
d) 6.0 – 10.0 mm
Answer: a
Explanation: Stand-off distance in Abrasive water jet machining will vary between 1 – 2 mm.

120. Impact angle in Abrasive water jet machining range between which of the following
values?
a) 0&#176 to 10&#176
b) 10&#176 to 30&#176
c) 30&#176 to 90&#176
d) 90&#176 to 100&#176
Answer: c
Explanation: Machine impact angle in AWJM will range between 30&#176 to 90&#176.
121. Of the following values, between which values traverse speed will range?
M
a) 0.1 to 5 m/min
b) 5 to 100 m/min
c) 100 to 500 m/min
O
d) 500 to 1000 m/min
C
Answer: b
Explanation: Value of traverse speed ranges between 5 to 100 m/min.
T.
122. Depth of cut values in Abrasive water jet machining ranges between which values?
O
a) 0.01 to 2 mm
b) 2 to 250 mm SP
c) 300 to 500 mm
d) 650 to 900 mm
Answer: b
G
Explanation: The value of depth of cut in AWJM ranges between 2 to 250 mm.
LO
Ultrasonic Machining (USM) – Introduction

123. Who discovered USM?
a) Balamuth
.B
b) Paul O Flawer
c) Turing
d) Steve John
17
Answer: a
Explanation: Balamuth was the scientist, who discovered Ultrasonic Machining.
-R
124. What is the full form of USM in advanced machining process?

a) Ultrasound manufacturing
b) Ultrasonic machining
SE
c) UV spectrum manufacturing
d) Ultra sonar machining
Answer: b
Explanation: Full form of USM in advanced machining processes, is Ultrasonic
C
machining.
125. USM removes materials using the ____________ tool.

a) Perpendicularly rotating
b) Perpendicularly oscillating
c) Axially oscillating
d) Inclined oscillating
Answer: c
Explanation: Material is removed using axial oscillating tool.

126. Which is softer material in USM?

a) Tool
b) Work piece
c) Tool & Work piece
Answer: a
Explanation: Tool is softer than work piece in USM.
127. Frequency of tool’s oscillation in USM ranges between ________

a) 5-10 kHz
b) 10-15 kHz
M
c) 18-20 kHz
d) 25-50 kHz
Answer: c
O
Explanation: Frequency used in USM is between 18 – 20 kHz.
C
128. Amplitude of oscillation of tool in USM ranges between ________
a) 0.1-10 μm
T.
b) 10-40 μm
c) 50-100 μm
d) 100-1000 μm
O
Answer: b
Explanation: The optimal range used is between 10-40 μm.
SP
129. In which year, discovery of USM took place?
a) 1910
G
b) 1925
c) 1943
LO
d) 1945
Answer: d
Explanation: Ultrasonic Machining was discovered in 1945.
.B
USM – Machining System

130. The machining system of USM contains which of the following components?
17
a) Magnetostrictor
b) Concentrator
c) Tools and slurry
-R

Answer: d
Explanation: In machining system of USM, the above mentioned components have to be
SE
present.
131. In Ultrasonic Machining, Magnetostrictor is energized at ultrasonic frequency.

a) True
C
b) False
Answer: a
Explanation: To oscillate, magnetostrictor must be energized to ultrasonic frequency in
USM.
132. Of the following scientists, who discovered magnetostrictor effect?

a) Balamuth
b) Steve O Flawer
c) Joule
d) Turing

Answer: c
Explanation: This effect was discovered by Joule in 1874 at Manchester.
133. In Ultrasonic Machining, magnetostrictor converts magnetic energy into which type
of energy?
a) Mechanical energy
b) Electrical energy
c) Thermal energy
Answer: a
Explanation: Oscillation of magnetostrictor takes place by converting magnetic energy to
M
mechanical energy.
134. What is the value of the amplitude obtained without mechanical amplifier?
O
a) 0.0001 – 0.001 µm
b) 0.001 – 0.1 µm
C
c) 1 – 10 µm
d) 10 – 100 µm
T.
Answer: b
Explanation: Relatively very small amplitudes are obtained without amplifier.
O
135. What is the value of the amplitude obtained when we use mechanical amplifier?
a) 1 – 10 µm
SP
b) 10 – 40 µm
c) 40 – 50 µm
d) 50 – 100 µm
G
Answer: c
Explanation: Relatively larger amplitudes are obtained when amplifier is used.
LO
136. In USM, tool tips must have low resistance and fatigue strength.
a) True
b) False
.B
Answer: b
Explanation: In USM, tool tips should must have high wear resistance and fatigue
17
strength.
137. At what rate slurry is pumped through nozzle in USM?

a) 10 L/min
-R
b) 25 L/min
c) 50 L/min
d) 75 L/min
SE
Answer: b
Explanation: Slurry is pumped through nozzle at the rate of 25 L/min, L- litres.
C
USM – Material Removal

138. By which of the following means, material is removed in USM?
a) Mechanical abrasion
b) Microchipping
c) Cavitation
Answer: d
Explanation: In Ultrasonic Machining, material is removed by any of the above means.

139. What is the percentage of contribution of cavitation to the total material removed?
a) <5%
b) 5 – 10 %
c) 10 – 20 %
d) 20 – 50 %
Answer: a
Explanation: Cavitation contributes to only less than 5 % of total material removed.
140. In the following mechanisms, which one is dominant in material removal?

a) Hammering
b) Cavitation
M
c) Microchipping
Answer: a
O
Explanation: Hammering is dominant mechanism in material removal of USM.
C
141. When machining porous material, which type of mechanism is introduces?
a) Abrasion
T.
b) Erosion
c) Corrosion
O
d) Vaporization
Answer: b SP
Explanation: Material removal of porous material takes place by erosion.
142. The rate of material removal depends on which of the following features?
a) Frequency
G
b) Static Pressure
c) Machining area
LO

Answer: d
Explanation: Material removal rate depends on all the above mentioned factors.
.B
143. The machinability of USM depends on brittleness criterion.

a) True
17
b) False
Answer: a
Explanation: Both machinability and MRR depends on brittleness of material. b) False
-R
144. Which of the following are the features of tool affecting MRR in USM?
a) Hardness
b) Wearability
SE
c) Accuracy
d) Mounting
Answer: d
C
Explanation: Different features of tool also affect the material removal in USM.
145. What is the Machinability rate of glass by USM?

a) 25%
b) 50%
c) 75%
d) 100%
Answer: d
Explanation: In the case of brittle materials, Ultrasonic Machining’s MRR is very high.
USM – Factors Affecting MRR

146. What happens to MRR with increase in tool amplitude?

a) Increases
b) Decreases
c) Remains same
Answer: a
Explanation: As amplitude of the tool increases, rate of material removal increases.
147. The vibration amplitude determines, which parameter of the abrasive particles?
a) Force
b) Torque
M
c) Velocity
d) Pressure
Answer: c
O
Explanation: Amplitude determines the velocity of abrasive particles between tool and
work piece.
C
148. If splashing occurs, it will result in an increase of material removal rate in USM.
T.
a) True
b) False
O
Answer: b
Explanation: Splashing occurs if amplitude is very high which in turn decreases the
SP
material removal rate.
149. Amplitude of the oscillation ranges between which of the following values?
a) 0.01 – 0.04 mm
G
b) 0.04 – 0.08 mm
c) 0.08 – 0.10 mm
LO
d) 0.10 – 0.20 mm
Answer: b
Explanation: Optimum value of the amplitude of the tool will vary between 0.04-0.08
mm.
.B
150. As the vibration frequency increases, what happens to material removal rate?
a) Decreases
17
b) Increases
d) Decrease and then increase
Answer: c
-R
Explanation: Up to a certain limit of vibration frequency, MRR increases and after that it
decreases.
SE
151. Which of the following can be used as an abrasive carrying medium?

a) Water
b) Benzene
C
c) Glycerol
Answer: d
Explanation: Any of the above liquids can be used as abrasive carrying medium.
152. If there is an increase in viscosity of slurry, what happens to MRR?

a) Increases
b) Decreases
c) Remains same

Answer: b
Explanation: As viscosity is increased, material removal rate is decreased.
153. How much percent of the abrasives are recommended in general for abrasive
medium?
a) 10 – 15 %
b) 15 – 20 %
c) 25 – 30 %
Answer: d
Explanation: In practice, volumetric concentration of abrasives used range between 30 – 35
%.d) 30 – 35 %
M
154. Machining rate can be affected by the ratio of hardness of tool to that of hardness of
work piece.
O
a) True
b) False
C
Answer: a
Explanation: In USM, Machining rate increases as the mentioned ratio decreases and
T.
vice-versa.
O
155. As the tool area increases, what happens to MRR?
a) Decreases SP
b) Increases
c) Remains same
Answer: a
G
Explanation: An increase in tool area distributes grains over the work piece, which
reduces the machining rate.
LO
156. When the static pressure of the feed is increases, what happens to MRR?
a) Increases
b) Decreases
.B
c) Increase up to a limiting condition

d) Decrease up to a limiting condition
17
Answer: c
Explanation: As static feed pressure increases, MRR increases up to a limiting condition
and then no further increase takes place.
-R
157. Which of the following distribution factors, does not affect the machining parts?
a) Side wear of tool
b) Abrasive wear
SE
c) Accurate feed
d) Form error of tool
Answer: c
C
Explanation: Inaccurate feed is the factor that affects the accuracy of machining parts.
USM – Dimensional Accuracy and Surface Quality

158. Which one of the following factors affects the accuracy of parts?
a) Steady abrasive flow
b) Accurate feed
c) Unsteady abrasive flow
d) Ultrasonic frequency
Answer: c
Explanation: Unsteady and uneven abrasive flow affects the dimensional accuracy.

159. State whether the statement is true or false.

“Hole oversize measures the difference between hole diameter measured at the bottom
surface, and the tool diameter.”
a) True
b) False
Answer: b
Explanation: Oversize measures the difference of the hole diameter measured at top
surface
160. While machining W4C and glass, tool over cut size when compared to mean grain
M
size is?
a) Two times greater
b) Two times smaller
O
c) Three times greater
d) Three times smaller
C
Answer: a
Explanation: Tool over cut size is 2 or 4 times greater than mean grain size.
T.
161. While machining B4C, tool over cut size when compared to mean grain size is?
O
a) Two times greater
b) Two times smaller SP
c) Three times greater
d) Three times smaller
Answer: c
Explanation: Tool over cut is 3 times greater than mean grain size while machining B4C.
G
162. In the following USM accuracy levels are limited to which value?
LO
a) ± 0.01 mm
b) ± 0.05 mm
c) ± 0.10 mm
d) ± 0.50 mm
.B
Answer: b
Explanation: In Ultrasonic Machining the dimensional accuracy levels are limited to ±
17
0.05mm.
163. Conicity resulting after machining by Ultrasonic Machining can be reduced by?
a) Direct injection of slurry
-R
b) Tools having negative taper

c) High static pressure
SE
Answer: d
Explanation: Conicity can be reduced by above means and also by using wear resistant
tools, finer abrasive particles etc.
C
164. Typical roundness error in graphite, resulted due to lateral vibrations is between?
a) 01 – 20 μm
b) 20 – 60 μm
c) 60 – 100 μm
d) 100 – 150 μm
Answer: b
Explanation: The roundness is between 20 – 60 μm while machining graphite by
Ultrasonic Machining.

165. Typical roundness error in glass, resulted due to lateral vibrations is between?
a) 01 –20 μm
b) 20 – 40 μm
c) 40 – 140 μm
Answer: c
Explanation: The roundness is between 40 – 140 μm while machining graphite by
Ultrasonic Machining.d) 150 – 250 μm
166. Which of the following factors affect the surface finish of machined parts in Ultrasonic
Machining?
a) Amplitude
M
b) Material
c) Tool surface
O
Answer: d
Explanation: The above factors influence the surface quality of the machined parts in
C
Ultrasonic Machining very significantly.
T.
167. What is value of surface finish achieved, when we use the abrasive of grit number
240?
a) 0.01 – 0.08 μm
O
b) 0.08 – 0.13 μm
c) 0.13 – 0.25 μm
SP
Answer: d
Explanation: The surface roughness obtained, when machined using abrasive of grit number
240, is between 0.25 – 0.38 μm.d) 0.25 – 0.38 μm
G
168. When the viscosity of liquid carrier is increased, the surface quality of the parts?
LO
a) Increased
b) Decreased
c) Remained same
.B
Answer: c
Explanation: As the viscosity of the liquid carriers reduces we can obtain smoother
17
surfaces.
USM – Applications
169. Ultrasonic Machining can be used for which of the following processes and
-R
applications?
a) Drilling
SE
b) Sinking and contouring

c) Polishing
Answer: d
C
Explanation: Ultrasonic Machining can be used for drilling holes, sinking, contouring and
many more wide variety of applications.
170. What is the limit of surface area that is to be machined using USM?
a) <100 mm2
b) <500 mm2
c) <1000 mm2
d) <1500 mm2

Answer: c
Explanation: If the surface area to be machined is above 1000 mm2, this type of
machining will not be apt for the parts.
171. Drilling in Ultrasonic Machining is done, by which motion of the tool?

a) Only rotation
b) Only oscillation
c) Oscillation and rotation
Answer: c
Explanation: The process, which uses USM for drilling, is known as Rotary Ultrasonic
M
Machining (RUM).
172. In which of the following materials, Rotary Ultrasonic Machining can be used to drill
O
holes through them?
a) Glass
C
b) Alumina
c) Ferrite
T.
Answer: d
O
Explanation: Rotary Ultrasonic Machining can be used to drill holes in the above
mentioned materials. SP
“Rotary Ultrasonic Machining is the process in which, interrupted drilling of small-diameter
holes takes place.”
G
a) True
b) False
LO
Answer: b
Explanation: Rotary Ultrasonic Machining is the process in which, uninterrupted drilling
takes place unlike traditional drilling.
.B
174. On which of the following features of cavity, will the penetration depth depend on?
17
a) Depth
b) Diameter
c) Size
d) All of the mentioned.
-R
Answer: d
Explanation: Penetration rate depends on cavity’s depth and size of the cavity i.e.., area
and volume, which can be determined by diameter.
SE
175. What is the value of depth in Ultrasonic sinking, after which, material removal
becomes difficult?
C
a) 1 to 2 mm
b) 2 to 5 mm
c) 5 to 7 mm
d) 7 to 10 mm
Answer: c
Explanation: After a depth of 5 to 7 mm, in USM sinking, material removal becomes very
difficult.
176. In production of EDM electrodes, typical ultrasonic speeds, in graphite ranges

between?
a) 0.01 – 0.10 cm/min

b) 0.10 – 0.25 cm/min

c) 0.25 – 0.40 cm/min
d) 0.40 – 1.40 cm/min
Answer: d
Explanation: Typical ultrasonic speeds used are between 0.4 – 1.4 cm/min, used in
producing EDM electrodes.
177. How much is the value of surface finished, achieved using Ultrasonic Polishing?
a) 0.1 μm
b) 0.3 μm
c) 0.5 μm
d) 0.7 μm
M
Answer: b
Explanation: Using Ultrasonic Polishing, very low values of surface finish can be
O
obtained, which may be very low as 0.3 μm.
C
178. In Micro-Ultrasonic Machining, which of the following component vibrates?
a) Tool
T.
b) Work piece
c) Feed pipe
O
Answer: b
Explanation: Unlike the normal Ultrasonic Machining, Micro-USM utilizes the work piece’s
SP
vibration and the rotation of the tool.
179. In Micro-USM, using WC tool, what is the value of diameter can be achieved?
G
a) 1 μm
b) 3 μm
LO
c) 5 μm
d) 7 μm
Answer: c
Explanation: Diameter value up to 5 μm can be achieved, using Micro-ultrasonic
.B
machining on glass, silicon and quartz materials.

17
-R
SE
C

R2017
UNIT II - THERMAL AND ELECTRICAL ENERGY BASED PROCESSES
[Syllabus]
[Electric Discharge Machining (EDM) – Wire cut EDM – Working Principle-equipments-

Process Parameters-Surface Finish and MRR- electrode / Tool – Power and control Circuits-
M
Tool Wear – Dielectric – Flushing –– Applications. Laser Beam machining and drilling,
(LBM), plasma, Arc machining (PAM) and Electron Beam Machining (EBM). Principles –
Equipment –Types - Beam control techniques – Applications]
O
Electric Discharge Machining (EDM) – Introduction
C
1. In advanced machining processes, what is the full form of EDM?
T.
a) Electro discharge Machining
b) Electro discharge Manufacturing
c) Electrical dimensioning Machining
O
d) Electrode dimensions Manufacturing SP
Answer: a
Explanation: Full form of EDM in advanced machining processes is, Electrodischarge
machining.
G
2. The evolution of wire EDM took place in which part of history?

LO
a) 1940s
b) 1950s
c) 1960s
d) 1970s
.B
Answer: d
Explanation: Evolution of wire EDM in 1970s was due to powerful generators, new wire
17
electrodes, improved machining intelligence and better flushing.
3. Machining speeds have gone up to how many times after the invention of EDM?
-R
a) Ten
b) Twenty
c) Thirty
SE
d) Fifty
Answer: b
Explanation: Machining speeds have gone up to 20 times after the invention of EDM.
C
4. By using EDM, how much percentage of machining costs can be reduced?

a) 10 %
b) 20 %
c) 30 %
d) 50 %
Answer: c
Explanation: EDM decreased the machined cost at least by 30 %.

5. After invention of EDM, surface finish have improved by how much factor?
a) 10
b) 15
c) 20
d) 25
Answer: b
Explanation: Surface finish have been improved by a factor of 15 after the invention of EDM.
6. Cavities with, which of the following factors can be produced using Electro discharge
machining?
M
a) Thin walls
b) Fine features
c) Thin walls & Fine features
O
C
Answer: c
Explanation: Cavities with thin walls and fine features can be machined using EDM.
T.
7. Which of the following geometries can be machined using EDM?
O
a) Simple
b) Complex SP
c) Difficult to cut
Answer: d
G
Explanation: Electrodischarge machining can be used for simple as well as complex
geometries.
LO
8. State whether the following statement is true or false regarding EDM.

“In EDM, process is affected by hardness of material.”
a) True
.B
b) False
17
Answer: b
Explanation: EDM process is not affected by the hardness of material.
9. How much amount of burr is produced in this process?

-R
a) 10 %
b) 40 %
c) 70 %
SE
d) No burr
Answer: d
C
Explanation: Electro discharge machining is a burr free process.
10. Which of the following mechanisms is used for material removal?

a) Electro discharge erosion
b) Magnetic abrasion
c) Electro chemical dissolution
d) Mechanical erosion
Answer: a
Explanation: Material is removed by electro-discharge erosion (EDE) in EDM

EDM-Mechanism of Material Removal

11. What is the value of order of frequency applied between the two electrodes in EDM?
a) 1 kHz
b) 3 kHz
c) 5 kHz
d) 7 kHz
Answer: c
Explanation: The magnitude of frequency applied between the electrodes in EDM is about 5
kHz.
M
12. What are the magnitude of voltages used in Electro discharge machining?
a) 1 to 20 V
O
b) 20 to 120 V
c) 120 to 220 V
C
d) 220 to 320 V
T.
Answer: b
Explanation: In EDM, the magnitude of voltages range between 20 and 120 V.
O
13. What are the values of gaps between the electrodes in EDM?
a) 0.001 – 0.05 mm
b) 0.01 – 0.5 mm
SP
c) 0.1 – 5 mm
d) 1 – 15 mm
G
Answer: b
Explanation: In EDM, very small gaps that range between 0.01 – 0.5 mm are maintained.
LO
14. How is material removed in Electro discharge machining?

a) Melt and evaporate
.B
b) Corrode and break

c) Mechanical erosion takes place
17
Answer: a
Explanation: In Electro discharge machining, material is melted and then evaporated.
-R
15. What is the radius of channel, when electrical breakdown occur?

a) 4 µm
SE
b) 6 µm
c) 8 µm
d) 10 µm
C
Answer: d
Explanation: In EDM, the electrical breakdown occurs in dielectric in a channel of radius
about 10 µm.
“In EDM, negative ions (electrons) collide with positive ions to generate heat.”
a) True
b) False

Answer: b
Explanation: In Electro discharge machining, electrons collide with neutral atoms producing
positive ions and further electrons.
17. What are the values of temperature that are obtained while machining using EDM?
a) 2000 to 3000ᵒC
b) 4000 to 6000ᵒC
c) 8000 to 12000ᵒC
d) 15000 to 20000ᵒC
Answer: c
Explanation: The temperatures obtained when the ions reach their respective electrodes,
M
range between 8000ᵒC and 12000ᵒC.
O
18. What range of heat fluxes are obtained while machining using EDM?
a) 1017 W/m2
C
b) 1019 W/m2
c) 1024 W/m2
T.
d) 1027 W/m2
O
Answer: a
Explanation: Heat flux up to the value of 10 17 W/m2 are obtained in EDM.
SP
19. What is the duration of sparks that are produced in Electro discharge machining?
a) 0.001 – 1 µs
b) 0.1 – 2000 µs
G
c) 0.2 – 100 ms
d) 100 – 2000 ms
LO
Answer: b
Explanation: Duration of spark in Electro discharge machining is about 0.1 to 2000 µs.
.B
20. State whether the following statement is true or false about material removal in EDM.
“In EDM, high pressures allow the metal to evaporate.”
17
a) True
b) False
Answer: b
-R
Explanation: High pressures in EDM try to prevent the super-heated metal from evaporation.
21. What are the values of pressure of the plasma in EDM?

SE
a) Up to 2 atm
b) Up to 20 atm
c) Up to 200 atm
C
d) Up to 2000 atm
Answer: c
Explanation: Pressure on the plasma channel rises to values as high as 200 atm when
dielectric evaporates.
22. At the end of pulse, super-heated metal evaporates _______________

a) Explosively
b) Normally
c) Periodically

d) Occasionally
Answer: a
Explanation: At the end of pulse, pressure drops suddenly and super-heated metal
evaporates explosively.
23. After the explosion is over, how is the debris carried away?
a) Evaporation
b) Fresh dielectric
c) Old dielectric
M
Answer: b
Explanation: Debris is carried away by the fresh dielectric that rushes in.
O
24. The layer formed when un expelled molten metal solidifies is known as ___________
C
a) Reabsorbed layer
T.
b) Recast layer
c) Un evaporated layer
d) Condensed layer
O
Answer: b
SP
Explanation: Unexpelled molten metal solidifies to form a layer known as recast layer.
25. Amount of material removed from anode and cathode depend on which of the following?
a) Electrons
G
b) Positive ions
c) Electrons & Positive ions
LO
Answer: c
.B
Explanation: The amount of material removed from electrodes depend on the contribution of
the charged ions.
17
26. What happens when the electron current predominates in the discharge?
a) More anodic removal
b) More cathodic removal
-R
c) Remains same
SE
Answer: a
Explanation: When electron current predominates the electrical discharge, anodic material
removal is greater than cathodic material.
C
27. Between what values mentioned below, do the discharges and sparks usually vary?
a) 1 and 10,000
b) 500 and 500,000
c) 500,000 and 1,000,000
Answer: b
Explanation: Frequency of discharges or sparks generally vary between 500 and 500,000
sparks per second.

28. What is the value of gap maintained between the electrodes when we use servo
mechanism?
a) 10 – 100 µm
b) 100 – 200 µm
c) 200 – 500 µm
d) 500 – 1000 µm
Answer: c
Explanation: In EDM, value of gap maintained between the electrodes range between 200
and 500 µm.
M
29. Based on the electrode gap, which of the following electric pulses are generated?
a) Open Circuit pulses
b) Sparks
O
c) Arcs
C
Answer: d
T.
Explanation: Based on the electrode gap, electric pulses are distinguished which are – circuit
pulses, sparks, arcs and short circuits.
O
“In Electro discharge machining, electric pulses generated affect the material removal.”
SP
a) True
b) False
G
Answer: a
Explanation: In Electro discharge machining, electric pulses generated have an impact on
LO
the material removal.
31. Open gap voltages contribute to how much amount of material removal?
a) 20 %
.B
b) 50 %
c) 70 %
17
d) No contribution
Answer: d
Explanation: Open gap voltage that occur at too large distances do not contribute to any
-R
material removal.
32. When the electrode gap is too small or electrodes are in contact, how much material is
SE
removed?
a) 10%
b) 20%
C
c) 30%
d) No material removed
Answer: d
Explanation: When electrodes come in contact with one another, short circuits occur and
material removed is not possible.
33. Which components mentioned below are affected due to arcs?

a) Work piece
b) Tool
c) Work piece & Tool

Answer: c
Explanation: Arcs are believed to occur at same spots on electrode surfaces which damage
both tool and work piece.
34. Which of the following pulses contribute to the desired material removal in EDM?
a) Open circuit pulses
b) Short circuits
c) Arcs
d) Sparks
M
Answer: d
Explanation: The sparks are the one which contributes to the desired material removal in
O
Electro discharge machining.
C
EDM-Machining System
T.
35. Which of the following are main components of EDM?
a) Dielectric system
b) Servomechanism
O
c) Power supply
SP
Answer: d
Explanation: Main components of machining system in EDM are – dielectric system, power
supply and servomechanism.
G
36. What is the function of feed-control system in Electro discharge machining?

LO
a) Constant gap
b) Supply power
c) Dielectric fluid supply
.B
d) Work piece holding
Answer: a
17
Explanation: Feed control system is used to maintain constant gap between electrodes.
37. What is the use of power supply system in Electro discharge machining?
-R
a) Constant gap
b) Supply power
SE
Answer: b
Explanation: Power supply system is used to supply pulses at certain voltages, current, on
C
time and off time.
38. What is the function of dielectric circulation unit in Electro discharge machining?
a) Constant gap
b) Supply power
Answer: c
Explanation: Dielectric circulation unit is used to supply dielectric fluid for flushing.

39. Which of the following materials are used as electrodes in EDM?

a) Graphite
b) Copper
c) Brass
Answer: d
Explanation: All the materials mentioned above, can be used as electrodes in Electro
discharge machining.
40. Metals with _________ melting point and _________ electrical conductivity are chosen
M
as tools in EDM.
a) Low, good
b) Low, bad
O
c) High, good
d) High, bad
C
Answer: c
T.
Explanation: In EDM, metals with high melting point and good electrical conductivity are
used as tools.
O
41. Copper has _________ Electro discharge machining wear and _________ conductivity.
SP
a) Good, better
b) Good, worse
c) Bad, better
d) Bad, worse
G
Answer: a
LO
Explanation: Cu is the metal which has better conductivity and good electro discharge
machining wear.
42. Which of the following tungsten carbides are used as electrodes in EDM?
.B
a) Silver tungsten
b) Copper tungsten
17

Answer: c
-R
Explanation: Both Silver tungsten and copper tungsten are the tungsten carbides used in
EDM.
SE
43. State whether the following statement is true or false regarding materials used in Electro
“In metals, copper graphite has less electrical conductivity than graphite.”
C
a) True
b) False
Answer: b
Explanation: Copper graphite has better electrical conductivity than graphite.
44. Brass metal ensures which type of sparking conditions in Electro discharge machining?
a) Stable
b) Unstable
c) Unsteady

d) Insecure
Answer: a
Explanation: Brass is a type of metal which ensures stable sparking conditions in Electro
45. In addition to the feed of tool, Electro discharge machining tool can have which type of
motion?
a) Oscillatory
b) Rotary
c) Vibrational
M
Answer: b
O
Explanation: In addition to feed, the tool electrode may have rotary or orbiting motion.
C
46. Which of the following parameters determines the size of cavities?
a) Size of electrode
T.
b) Radius of orbit
O
Answer: c
SP
Explanation: Size of electrode and radius of orbit determines the size of cavities in EDM.
47. Electrode orbiting ________ the flushing of dielectric fluid in Electro discharge
G
machining.
a) Improves
LO
b) Decreases
c) Reduces
d) Degrades
.B
Answer: a
Explanation: The additional orbiting motion of electrodes helps in improving the flushing by
17
creating a pumping effect of dielectric liquid.
48. Quality of hole produced by orbiting motion is _________ to that obtained by using
stationary electrode.
-R
a) Inferior
b) Superior
c) Lower
SE
Answer: b
C
Explanation: Quality of hole produced by orbiting motion is superior to that obtained by using
stationary electrode.
49. In EDM, electrode polarity depends up on which of the following components?

a) Work piece
b) Electrode material

Answer: c
Explanation: In Electro discharge machining, electrode polarity depends on both work piece
and electrode material
50. Which one among the following, is the most important factor in determining the tool
wear?
a) Melting point
b) Boiling point
c) Power supplied
d) Feed rate
M
Answer: a
Explanation: In EDM, melting point is the most important factor in determining the tool wear.
O
51. Electrode wear ratios can be expressed as, which of the following wears?
a) End wear
C
b) Side wear
c) Corner wear
T.
O
Answer: d
Explanation: Electrode wear ratios are expressed as end wear, corner wear, side wear and
SP
volume wear.
52. The term no wear in EDM occurs when electro-to-work piece wear ratio is __________
a) <1%
G
b) <3%
c) <5%
LO
d) <10%
Answer: a
Explanation: In Electro discharge machining, no wear is the term used when the electrode-
.B
to-work piece ratio is less than 1%.

17
53. Which of the following are the other factors that influence the electrode wear?
a) Voltage
b) Current
c) Electrode material
-R
Answer: d
SE
Explanation: In EDM, electrode wear depends on the factors such as voltage, current,
electrode material and polarity.
C
54. State whether the following statement is true or false regarding wear in EDM.
“In EDM, electrode wear is less dominant when it comes to micromachining
applications.”
a) True
b) False
Answer: b
Explanation: Electrode wear is more when it comes to micromachining applications in EDM.
55. State whether the following statement is true or false regarding wear in EDM.
“In EDM, corner wear ratio does not depend on type of electrode material.”
a) True
10

b) False
Answer: b
Explanation: In EDM, corner wear ratio depend on the material of electrode used.
56. In Electro discharge machining, highest wear ratio is associated with which type of
melting point?
a) Low
b) Medium
c) High
d) Very high
M
Answer: a
Explanation: In Electro discharge machining, lowering of the melting point of electrode
O
material results in high wear ratio.
C
57. Which of the following is not a function of dielectric in EDM?
a) Flush particles
T.
b) Cool the section
c) Maintain voltage
O
d) Provide insulation
Answer: c
SP
Explanation: Flushing particles, providing insulation and cooling the sections that are heated,
are the functions of dielectric.
G
58. Which of the following are the main requirements of dielectric fluids?
a) Viscosity
LO
b) High flash point

c) Minimum odour
.B
Answer: d
Explanation: Adequate viscosity, high flash point, oxidation stability, minimum odour, low
17
cost and good electrical discharge are the main requirements of dielectric fluids.
59. Which of the following can be used as dielectric fluids in EDM?

a) Kerosene
-R
b) Silicon fluids
c) Distilled water
SE
Answer: d
Explanation: The dielectric fluids used are kerosene, silicon fluid, ethylene glycol, water in
C
emulsions and distilled water.
60. In EDM, inadequate flushing will not result in which of the following consequences?
a) Arcing
b) Debris removal
c) Decrease electrode life
d) Increased production time
Answer: b
Explanation: Inadequate flushing in Electro discharge machining results in less removal or
no removal of debris.
11

61. Which methods below, are used for introducing the dielectric in machining gap?
a) Normal flow
b) Reverse flow
c) Jet flushing
Answer: d
Explanation: Four methods namely normal flow, reverse flow, jet flushing and immersion
flushing are used for introducing dielectric.
M
62. Few large holes are _________ than many small flushing holes in Electro discharge
machining.
a) Worse
O
b) Better
c) Well
C
T.
Answer: a
Explanation: Many small holes are better than a few large holes in machining thorough the
O
EDM process.
SP
63. State whether the following statement is true or false regarding the dielectric in EDM.
“In EDM, flushing through the tool is more preferred than side flushing.”
a) True
b) False
G
Answer: a
LO
Explanation: Flushing through the tool is preferred than side flushing for deep cuts.
64. In Electro discharge machining, which type of dielectric flow mentioned below is
desirable?
.B
a) Unsteady flow
b) Steady flow
17
c) Unstable flow
Answer: b
-R
Explanation: In EDM, steady dielectric flow on the entire electrode-work piece interfaces is
most desirable
SE
EDM-Material Removal Rate

65. Metal is removed on which of the components in electro discharge machining?
a) Electrode tool
C
b) Work piece
c) Electrode tool & Work piece
Answer: c
Explanation: In Electro discharge machining, material is removed from both tool and work
piece.
66. On which of the following components, does the MRR depend?
a) Work piece
b) Electrode tool
12

c) Electrode tool & Work piece

Answer: c
Explanation: Material removal rate not only depends on work piece material but also the tool
material.
67. Which of the following factors influence the material removal rate?
a) Pulse condition
b) Electrode polarity
c) Machining medium
M
Answer: d
O
Explanation: The factors such as pulse conditions, electrode polarity and machining medium
also affect the material removal rate.
C
68. In Electro discharge machining, materials with low melting point have which type of
T.
material removal rate?
a) Very low
O
b) Low
c) Medium SP
d) High
Answer: d
Explanation: In Electro discharge machining, materials having low melting point have high
G
material removal rates and vice-versa.
LO
69. In Electro discharge machining, materials with low melting point have which type of
surface roughness?
a) Rough
b) Smooth
.B
c) Fine
17
Answer: a
Explanation: In Electro discharge machining, materials having low melting point have high
rougher surfaces and vice-versa.
-R
70. What are the values of material removal rates in EDM?

a) 0.001 to 0.1 mm3/min
SE
b) 0.1 to 400 mm3/min

c) 400 to 1000 mm3/min
d) 1000 to 5000 mm3/min
C
Answer: b
Explanation: In EDM, material removal rates range from 0.10 to 400 mm 3/min.
71. What happens to the material removal rate if the sparks are very less in EDM?
a) Decreases
b) Increases
13

Answer: a
Explanation: In EDM, if sparks generated are less then material removal rate decreases.
72. What is the relation between the melting point and the material removal rate?
a) Directly Proportional
b) Inversely proportional
c) Indirectly proportional
Answer: b
Explanation: In Electro discharge machining, material removal rate is inversely proportional
M
to the melting point.
73. What happens to the crater size if we increase the current keeping the pulse time
O
constant?
a) Increase
C
b) Decrease
c) Decrease and increase
T.
O
Answer: a
Explanation: By keeping pulse time constant and increasing current, crater size also
SP
increases.
74. What happens to the crater size if we decrease the pulse time keeping the current
constant?
G
a) Increase
b) Decrease
LO
c) Increase and decrease

Answer: b
.B
Explanation: By decreasing pulse time and keeping current constant, crater size also
decreases
17
EDM-Surface Integrity
75. On which of the following factors do the craters depend?
-R
a) Physical properties
b) Mechanical properties
c) Composition of medium
SE
Answer: d
Explanation: In EDM, craters depend on the physical and mechanical properties of material
C
and composition of medium.
76. The maximum depth of damaged layer is how many times that of average surface
roughness?
a) 1.5 time
b) 2 times
c) 2.5 times
d) 3 times
14

Answer: c
Explanation: Depth of damaged layer is two and half times the average surface roughness
value.
77. What happens to the surface roughness values if the MRR increases in EDM?
a) Increases
b) Decreases
c) Decrease and increase
Answer: a
M
Explanation: In EDM, the surface roughness values increases linearly with increase in the
material removal rates.
O
78. State whether the following statement is true or false regarding the surface roughness in
EDM.
C
“In EDM, graphite electrodes produce smoother surfaces than metal ones.”
a) True
T.
b) False
O
Answer: b
Explanation: In EDM, graphite electrodes produce rougher surfaces than that of the metal
SP
ones.
79. In Electro discharge machining, what happens to the surface finish if the pulse energy is
decreased?
G
a) Reduces
b) Decreases
LO
c) Improves
Answer: c
.B
Explanation: In Electro discharge machining, the surface finish improves if the pulse energy
is decreased.
17
80. Using of a mate electrode in Electro discharge machining _____________ the surface
roughness of material.
a) Increases
-R
b) Decreases
c) Enhances
SE
Answer: b
Explanation: By using a mate electrode in Electro discharge machining, the surface
C
roughness values are decreased.
81. What happens to the surface roughness if oxygen gas is introduced in the gap?
a) Increases
b) Decreases
c) Decrease and then increase
Answer: b
Explanation: In EDM, surface roughness increases with the supply of oxygen gas in gaps.
15

82. By how much percent surface roughness is reduced if we use proper dielectric flow?
a) 25%
b) 50%
c) 75%
d) 100%
Answer: b
Explanation: In Electro discharge machining, if we use a proper dielectric fluid flow, surface
roughness is decreased by 50 percent.
83. What are the tolerance values obtained by machining using EDM?
M
a) ± 10 mm
b) ± 15 mm
c) ± 25 mm
O
d) ± 40 mm
C
Answer: c
Explanation: The tolerance values of ± 25 mm are obtained when we machine components
T.
using EDM.
O
84. How much extra tolerances are achieved when we choose proper variables?
a) ± 5 mm SP
b) ± 10 mm
c) ± 15 mm
d) ± 20 mm
G
Answer: a
Explanation: Extra tolerances of ± 5 mm are obtained with a proper choice of process
LO
variables
EDM-Heat Affected Zone (HAZ)

.B
85. What are the values of temperatures obtained in Electro discharge machining?
a) 1000 to 2000 oC
b) 2000 to 4000 oC
17
c) 4000 to 8000 oC
d) 8000 to 12000 oC
-R
Answer: d
Explanation: The temperature attained while machining in Electro discharge machining are
from 8000 to 12000 oC.
SE
86. What is the value of thickness of recast layer obtained when power of 5 µJ is given?
a) 1 µm
b) 3 µm
C
c) 5 µm
d) 7 µm
Answer: a
Explanation: When a power of 5 µJ is given, recast layer thickness of 1 µm is obtained.
87. What are the values of thickness of recast layers in Electro discharge machining?
a) 0.001 to 0.025 µm
b) 0.01 to 0.25 µm
c) 1 to 25 µm
16

d) 10 to 250 µm
Answer: c
Explanation: In Electro discharge machining, the value of thickness of recast layers ranges
from 1 to 25 µm.
88. In Electro discharge machining, some annealing of the work piece can be expected
__________ the machined surface.
a) On
b) Just below
c) Above
M
d) At bottom
Answer: b
O
Explanation: Annealing of some part of the work piece in EDM can be expected just below
the machined surface.
C
89. The depth of the annealed surface is __________ to the amount of power used in
T.
machining operation.
a) Directly proportional
O
b) Inversely proportional
c) Exponential SP
Answer: a
Explanation: The depth of annealed surface in EDM is proportional to the amount of power
G
used.
LO
90. What are the values of thickness of annealed surface obtained while machining using
EDM?
a) 1 to 25 µm
b) 50 to 200 µm
.B
c) 200 to 500 µm
d) 500 to 1000 µm
17
Answer: b
Explanation: Values of annealed surface thickness range from 50 µm to 200 µm.
-R
91. In EDM, choosing electrodes that produce which type of machining reduces the
annealing effect?
a) Stable
SE
b) Unstable
c) Uneven
C
Answer: a
Explanation: In Electro discharge machining, choosing the electrodes which produce more
stable machining reduces the annealing effect.
92. What happens to the fatigue strength of alloys if altered surfaces are produced in
Electro discharge machining?
a) Increases
b) Reduces
c) Enhances
17

d) Improves
Answer: b
Explanation: The altered surface layers that are produced in Electro discharge machining,
significantly reduces the fatigue strength of alloys.
93. The altered layers formed during the process of EDM consists of which of the following?
a) Tempered layers
b) Heat affected zones
c) Intergranular precipitates
M
Answer: d
Explanation: Altered layers consists of recast layers, tempered layers, HAZs and
O
intergranular precipitates in EDM.
C
94. During roughing process through Electro discharge machining, what is the thickness of
layer formed?
T.
a) <0.075 mm
b) <0.125 mm
O
c) <0.500 mm
d) <0.750 mm SP
Answer: b
Explanation: The thickness of layer obtained after machining is <0.127 mm in EDM.
G
95. During finishing process through Electro discharge machining, what is the value
thickness of layer formed?
LO
a) <0.075 mm
b) <0.125 mm
c) <0.500 mm
d) <0.750 mm
.B
Answer: a
17
Explanation: The thickness of layer obtained during EDM finishing is <0.075 mm.
96. Which of the following processes can be used for restoration of fatigue properties?
a) Low-stress grinding
-R
b) Chemical machining
c) Reheat treatment
SE
Answer: d
Explanation: For removal of altered layers processes such as low-stress grinding, chemical
C
machining, reheat treatment, metallurgical type coating and application of shot peening.
97. State whether the following statement is true or false regarding the HAZ in EDM.
“In EDM, post treatment to recover fatigue strength is not recommended.”
a) True
b) False
Answer: b
Explanation: After machining using EDM, post treatment to restore the fatigue strength is
recommended.
18

EDM-Applications
98. Which of the following shapes can be produced using Electro discharge machining?
a) Complex shapes
b) Simple shapes
Answer: c
Explanation: Electro discharge machining is used to machine complex shapes to a high
degree of accuracy.
M
99. Which of the following materials can be machined using Electro discharge machining?
a) Heat resistant alloys
b) Super alloys
O
c) Carbides
C
T.
Answer: d
Explanation: EDM is used to machine materials such as carbides, heat resistant and super
alloys which are difficult-to-machine materials.
O
100. Which of the following are the applications of Electro discharge machining?
a) Holes
SP
b) Slots
c) Texturing
G
Answer: d
LO
Explanation: Micromachining of holes, slots, dies, texturing, milling, surface modification and
mechanical pulsing are some typical applications of Electro discharge machining.
.B
101. State whether the following statement is true or false regarding the applications of
EDM.
“In advanced machining processes, the incorporation of EDM with CIM increased the
17
length of time for unit operation.”

a) True
b) False
-R
Answer: b
Explanation: The incorporation of EDM in CIM reduced the length of time per unit operation.
SE
102. Which type of electrode is used for drilling in Electro discharge machining?
a) Flat electrode
b) Cuboidal electrode
C
c) Tubular electrode
d) Spherical electrode
Answer: c
Explanation: Tubular electrode is mostly preferred in Electro discharge machining, for drilling
purpose.
103. The dielectric fluid is flushed in thorough which part of the electrode in drilling in EDM?
a) Interior hole
b) Side gaps
19

Answer: a
Explanation: EDM drilling uses a tubular electrode which flushes the dielectric thorough the
interior holes for removing debris.
104. Which type of holes can be produced through drilling using Electro discharge
machining?
a) Irregular
b) Curved
c) Tapered
M
Answer: d
O
Explanation: Drilling of work piece using EDM produced holes which can be irregular,
curved, tapered as well as inclined holes.
C
105. What are the values of general feed rates used for drilling in EDM?
T.
a) 0.1 mm/min
b) 0.3 m/min
O
c) 0.5 mm/min
d) 0.7 mm/min SP
Answer: a
Explanation: Usually a feed rate of 0.10 mm/min is used for drilling the work piece using
Electro discharge machining.
G
106. What are range of diameter values obtained by drilling using EDM?
LO
a) 0.01 to 0.05 mm
b) 0.1 to 0.5 mm
c) 1 to 5 mm
d) 10 to 15 mm
.B
Answer: b
17
Explanation: Diameter values while drilled using Electro discharge machining, ranges from
0.10 to 0.50 mm.
107. What are the values of overcuts left behind after drilling of work piece?
-R
a) 0.01 to 0.05 mm
b) 0.1 to 0.5 mm
c) 1 to 5 mm
SE
d) 10 to 15 mm
Answer: a
C
Explanation: Overcut values from 0.01 to 0.05 mm are obtained after the drilling process in
EDM.
108. Electro discharge sawing is an application of EDM which employs __________ as tool
material.
a) Steel band
b) Disc
c) Steel band & Disc
20

Answer: c
Explanation: Electro discharge sawing is an application of EDM which employs either steel
band or disc as tool.
109. When compared to the conventional abrasive sawing, how many times faster is the
MRR?
a) Twice
b) Thrice
c) Four
d) Five
M
Answer: a
Explanation: Electro discharge sawing cuts the work piece material at the rates which are
twice that of conventional abrasive sawing method.
O
110. How much amount of burr is produce while machined using Electro discharge
C
sawing?
a) 10%
T.
b) 20%
c) 50%
O
d) No Burr
Answer: d
SP
Explanation: The cuts produced in Electro discharge sawing have smaller kerf widths which
hav no burrs in it.
G
111. What are the values of finish obtained by machining work piece thorough Electro
discharge sawing?
LO
a) 0.1 to 4 µm
b) 6.3 to 10 µm
c) 12.4 to 23 µm
d) 25.6 to 40 µm
.B
Answer: b
17
Explanation: The finish obtained ranges from 6.3 to 10 µm when machined using Electro
discharge sawing.
112. What are the recast layer thickness values obtained in ED sawing?
-R
a) 0.001 to 0.022 mm
b) 0.025 to 0.130 mm
c) 0.236 to 0.352 mm
SE
d) 0.432 to 0.568 mm
Answer: b
C
Explanation: The recast layer thickness values obtained from ED sawing range from 0.025 to
0.13 mm
113. Which of the following electrodes are used for machining spherical surfaces in Electro
discharge machining?
a) Tubular electrodes
b) Flat electrodes
c) Cuboidal electrodes
21

Answer: a
Explanation: Simple tubular electrodes are used to machine convex and concave spherical
surfaces.
114. What are the values of dimensional accuracy obtained while machining spherical
surfaces?
a) ± 1 µm
b) ± 3 µm
c) ± 5 µm
d) ± 7 µm
M
Answer: a
Explanation: Dimensional accuracy of ± 1 µm is obtained while machining spherical surfaces
using EDM.
O
115. What are the surface roughness values obtained while machining spherical surfaces
C
using Electro discharge machining?
a) <0.1 µm
T.
b) <0.3 µm
c) <0.5 µm
O
d) <0.7 µm
Answer: a
SP
Explanation: The surface roughness values obtained while machining of spherical surfaces
are <0.1 µm in Electro discharge machining.
G
116. Which motion of tool is used for machining spherical surfaces in Electro discharge
machining?
LO
a) Oscillatory
b) Vibratory
c) Rotary
.B
Answer: c
17
Explanation: The rotary motion tool is used for machining spherical surfaces of conducting
ceramic materials in EDM.
117. Which type of electrodes are used for milling application in Electro discharge
-R
machining process?
a) Tubular type electrodes
b) Cylindrical type electrodes
SE
c) Flat type electrodes

d) Spherical type electrodes
C
Answer: b
Explanation: Standard cylindrical electrodes are used for milling application in EDM process.
118. Which type of cavities can be machined using milling process by Electro discharge
machining?
a) Complex cavities
b) Simple cavities
c) Simple & Complex cavities
22

Answer: c
Explanation: Simple cavities and complex cavities are machined by successive NC sweeps
of electrode over the desired path.
119. The simple electrodes are rotated at which speed for milling of work pieces in Electro
discharge machining?
a) Very low
b) Low
c) Medium
d) High
M
Answer: d
Explanation: Simple electrodes are rotated at high speeds for milling in Electro discharge
machining same as that of conventional milling.
O
120. What happens to the dielectric flushing while milling tool is rotated at a high speed in
C
EDM?
a) Improved
T.
b) Worsen
c) Reduced
O
Answer: a
SP
Explanation: Milling by electro discharge machining enhances the dielectric flushing due to
high speed rotation of tool.
G
121. State whether the following statement is true or false regarding the applications of
EDM.
LO
“In EDM, milling process can machine complex shapes with sharp corners.”
a) True
b) False
.B
Answer: b
Explanation: EDM milling has a main limitation i.e.., it cannot machine complex shapes with
17
sharp tools because of rotating tool.
122. Which of the following are the steps included in the die sinking process of EDM?
a) CAD of electrode
-R
b) Electrode manufacturing
c) Programming for die sinking
SE
Answer: d
Explanation: Designing of electrode, then manufacturing, and programming of die sinking
C
are the steps to be followed for die sinking process in EDM.
123. Wire EDM is a special form of Electro discharge machining which contains
__________ electrode.
a) Continuously moving
b) Periodically moving
c) Discontinuously moving
23

Answer: a
Explanation: Wire EDM is a special type of EDM which uses a continuously moving
electrode for removal of material.
124. Which path of the components in wire EDM determines the path to be machined?
a) Horizontal worktable movement
b) Vertical worktable movement
c) Horizontal & Vertical worktable movement
Answer: a
M
Explanation: Horizontal movement of the work table determines the path to be machined in
Wire Electro discharge machining.
O
125. Which of the following materials are machined using Wire Electro discharge
machining?
C
a) Polycrystalline diamond
b) Cubic Boronitride
T.
c) Matrix composites
O
Answer: d SP
Explanation: Polycrystalline diamond (PCD), cubic boron nitride (CBN) and other matrix
composites are the material than can be machined using wire EDM.
126. How much amount of burr is produce when we use Wire Electro discharge machining
G
for machining of work pieces?
a) 10%
LO
b) 20%
c) No burr
d) Small amount
.B
Answer: c
Explanation: In Wire Electro discharge machining no burr is produced without any distortion
17
while machining work pieces.
127. Which of the following industries use wire EDM for different applications?
a) Chemical industry
-R
b) Aerospace industry
c) Automobile industry
SE
Answer: d
Explanation: Industries such as chemical, aerospace, automobile, nuclear etc.., use wire
C
EDM for a wide variety of applications in their industries
128. While machining insulating ceramic materials using EDM, where is the sheet metal
placed?
a) Over material
b) Below material
c) Under material
24

Answer: a
Explanation: Sheet metal is placed over the material in machining of insulating materials
using EDM.
129. Sparks occur between which of the following components?

a) Work piece and sheet metal
b) Tool electrode and sheet metal
c) Work piece and electrode
Answer: b
M
Explanation: Sparks occur between sheet metal and tool electrode for macining insulating
ceramics.
O
130. Texturing is applied to the steel sheets at which stages of cold rolling?
a) Initial stages
C
b) Middle stages
c) Final stages
T.
O
Answer: a
Explanation: At the final stages of cold rolling, texturing is applied to the steel sheets.
SP
131. What is the full form of EDT in EDM processes?
a) Electro discharge Tinplating
b) Electro discharge Texturing
G
c) Electro discharge Tapping
d) Electro discharge Turing
LO
Answer: b
Explanation: Electro Discharge Texturing is a variant of EDM which is the full form of EDT.
.B
132. Which of the following are the process variables for texturing process in EDM?
a) Pulse current
17
b) Electrode polarity
c) Dielectric type
-R
Answer: d
Explanation: Pulse current, polarity, dielectric, electrode material and roll rotation speed are
some process variables of texturing.
SE
133. What are the values of current amplitudes used in EDT?

a) 0.2 to 1 A
C
b) 2 to 10 A
c) 20 to 100 A
d) 40 to 200 A
Answer: b
Explanation: The values of current amplitudes in EDT range from 2 to 10 A.
134. What are duration values of current amplitude in EDT?

a) 0.1 to 1 µs
b) 1 to 10 µs
c) 10 to 100 µs
25

d) 100 to 1000 µs
Answer: c
Explanation: Duration of current amplitudes used for EDT range from 10 to 100 µs.
135. What are the spindle rotation speeds used in EDT?

a) 1 to 4 rpm
b) 10 to 40 rpm
c) 20 to 60 rpm
d) 30 to 90 rpm
M
Answer: b
Explanation: Spindle rotation speeds for EDT process range from 10 to 40 rpm.
O
136. What are the values of diameter which are machined using Micro-EDM?
a) 0.001 to 0.01 mm
C
b) 0.01 to 0.1 mm
c) 0.1 to 1 mm
T.
d) 1 to 10 mm
O
Answer: c
Explanation: Values of diameter in Micro-EDM range from 0.10 to 1.0 mm.
SP
137. What happens to the machine capital cost in EDT when there is an increase in tool
quantity?
a) Decreases
G
b) Increases
c) Remains same
LO
Answer: b
Explanation: With increase in tools quantity machine cost increases but texturing cost
.B
reduces.
17
138. What is the value of depth to diameter ratio in Micro-Electro discharge machining
process?
a) 10:1
b) 5:2
-R
c) 4:3
d) 2:1
SE
Answer: a
Explanation: Value of the depth to diameter ratio in Micro-Electro discharge machining is
about 10:1.
C
139. What are the values of depths that can be machined using Micro-EDM?
a) 1 mm
b) 10 mm
c) 100 mm
d) 1000 mm
Answer: c
Explanation: Micro-Electro discharge machining can machine up to a depth of 100 mm in the
work piece material.
26

140. What are the machining rates used in Micro-EDM process?

a) 0.1 to 2 mm/min
b) 1 to 20 mm/min
c) 10 to 200 mm/min
d) 100 to 500 mm/min
Answer: b
Explanation: Machining rates used in Micro-EDM process range from 1 to 20 mm/min.
141. What are the values of hole diameters obtained using Wire electro discharge grinding?
a) 1 µm
M
b) 3 µm
c) 5 µm
d) 7 µm
O
Answer: c
C
Explanation: Values of hole diameters up to 5 µm can be obtained using Wire electro
discharge grinding process.
T.
142. What are the feed rates used in WEDG process?
O
a) 1 to 5 mm/min
b) 5 to 10 mm/min SP
c) 10 to 15 mm/min
d) 15 to 20 mm/min
Answer: b
G
Explanation: Feed rate values in WEDG process range from 5 to 10 mm/min
LO
EDM-Process Control, Automation, Environmental Impact

143. Which of the following is a major difficulty in the Electro discharge machining process?
a) Proper sparks
.B
b) Abnormal discharges
c) Optimum feed rates
d) No burr
17
Answer: b
Explanation: Avoidance of abnormal discharges has become a major difficulty in Electro
-R
discharge machining process.
144. What has been done to the off time when there is a no-load voltage of electric
SE
discharge?
a) Increased
b) Decreased
c) Reduced
C
d) Remains same
Answer: a
Explanation: The off time of pulse is increased in order to avoid the abnormal electric
discharges.
145. In a simple application which of the following parameters are inputs?

a) Pulse duration and current
b) Normal and abnormal pulses
27

Answer: a
Explanation: Inputs used are pulse duration and current in a simple application.
146. In a simple application which of the following parameters are outputs?

a) Pulse duration and current
b) Normal and abnormal pulses
M
Answer: a
Explanation: Outputs used are normal and abnormal pulses in a simple application.
O
147. Which of the following are correlated with the machining conditions at output stage?
a) Machining depth
C
b) Surface roughness
c) Accuracy
T.
O
Answer: d
Explanation: Machining depth, surface roughness, accuracy are correlated with the
SP
machining conditions at the output stage.
148. How are EDM’s levels of integration when compared to conventional machining?
a) Slower rate
G
b) Faster rate
c) Same rate
LO
Answer: a
Explanation: EDM’s levels of computer integration is at a slower rate when compared to
.B
conventional machining processes.

17
149. Manufacturing of tool electrode undergoes which of the following processes?

a) Milling
b) Turning
c) Finishing
-R
Answer: d
SE
Explanation: The tool electrode manufacturing used in EDM has to undergo the basic
production processes such as milling, turning and finishing.
C
150. High temperatures produced in the working gap results in which of the following
potentials?
a) Hazardous smoke
b) Toxic vapours
c) Aerosols
Answer: d
Explanation: The temperatures in the working gap increases leading to hazardous smoke,
vapours and aerosols.
28

151. Hydro carbons present in the dielectric fluid have impact on which of the body parts?
a) Eyes
b) Teeth
c) Skin
d) Nails
Answer: c
Explanation: Hydrocarbons present in dielectric fluids of EDM will have a negative impact on
the skin in our body.
152. What happens to the Electro discharge machining process under unfavourable
M
working conditions?
a) Will remain stable
b) Explosion may occur
O
c) Machining rate increases
d) Nothing happens
C
Answer: b
T.
Explanation: Explosion occurs if Electro discharge machining is done under unfavourable
process variables and conditions.
O
153. Reduction in the electrical energy consumption will have impact on which aspects
SP
mentioned below?
a) Environmental
b) Economic
c) Environmental & Economic
G
LO
Answer: c
Explanation: The reduction of electric energy consumption has economic as well as
environmental benefits
.B
Wire-cut EDM
Wire-cut EDM
17
154. A thin metallic wire used in wire-cut EDM is kept submerged in a tank of _____
a) dielectric fluid
b) pure water
-R
c) molten metal
d) kerosene
SE
Answer: a
Explanation: The Wire Electric Discharge Machining (WEDM) is a variation of EDM and is
commonly known as wire-cut EDM or wire cutting. In this process, a thin metallic wire is fed
onto the workpiece, which is submerged in a tank of dielectric fluid such as deionized water.
C
155. Wire-cut EDM can cut plates of thickness upto _____

a) 50mm
b) 100mm
c) 300mm
d) 500mm
Answer: c
Explanation: Wire-cut EDM process can cut plates as thick as 300mm and is used for
29

making punches, tools and dies from hard metals that are difficult to machine with other
methods.
156. In WEDM, the wire is held tight between_____

a) upper and lower nozzles
b) upper and lower diamond guides
c) upper and lower groves in the handle
d) upper and lower pulleys
Answer: b
Explanation: In wire-cut EDM (WEDM), the wire which is constantly fed from a spool, is held
M
between upper and lower diamond guides. The guides are usually CNC-controlled and move
in the x–y plane.
O
157. The upper guide can move independently about_____
a) x-axis
C
b) y-axis
c) x-y-w axes
T.
d) z-u-v axes
O
Answer: d
Explanation: On most machines, the upper guide can move independently about the z–u–v
SP
axes, giving it the flexibility to cut tapered and transitioning shapes (example: square at the
bottom and circle on the top).
158. In the wire-cut EDM process, de-ionizing units are used for controlling the _____
G
a) feed rate
b) resistivity
LO
c) burr formation
d) temperature of the wire
Answer: b
.B
Explanation: In the wire-cut EDM process, water is commonly used as the dielectric fluid.
Filters and de-ionizing units are used for controlling the resistivity and other electrical
17
properties.
159. In the wire-cut EDM process, water is also used for _____
a) cooling
-R
b) increasing the feed rate

c) flushing away the burr
d) controlling the cutting speed
SE
Answer: c
Explanation: Apart from being used as a dielectric fluid, the water also helps in flushing away
C
the debris from the cutting zone. The flushing also helps to determine the feed rates to be
given for different thickness of the materials.
160. The WEDM process requires _____

a) lower initial investment
b) lesser cutting forces
c) a skilled operator
d) a coolant pump
30

Answer: b
Explanation: The wire-cut EDM process requires lesser cutting forces in material removal;
hence it is generally used when lower residual stresses in the workpiece are desired.
161. The materials which are not stress-relieved before machining by WEDM process can
get distorted during machining.
a) True
b) False
Answer: a
Explanation: If the energy/power pulse is relatively low (as in finishing operations), little
M
changes in the mechanical properties of the material are expected due to residual stresses.
The components which are not stress-relieved earlier can get distorted in the machining
process.
O
162. During the WEDM process, workpiece undergoes a number of thermal cycles.
C
a) True
b) False
T.
Answer: a
O
Explanation: In WEDM process, the selection of process parameters is very crucial, as in
some cases the workpiece undergoes significant thermal cycles the can be very severe.
SP
These thermal cycles can form recast layers and induce residual tensile stresses on the
workpiece.
163. Electrically conductive materials are cut by WEDM process by _____ mechanism.
G
a) thermal
b) electro-thermal
LO
c) electro-dynamic
d) fused metal
Answer: b
.B
Explanation: Electrically conductive materials are cut by WEDM process by an electro-

thermal mechanism. In the WEDM process, the motion of the wire is slow. It is fed in the
17
programmed path and material is removed from the workpiece accordingly
164. In wire-cut EDM process, material removal takes place by a series of discrete
-R
discharges between _____

a) di-electric fluid and the wire electrode
b) the wire-electrode and the workpiece
SE
c) the workpiece and the CNC-table

d) wire electrodes
Answer: b
C
Explanation: In wire-cut EDM process, material removal takes place by a series of discrete
discharges between the wire and the workpiece in the presence of a di-electric fluid. Water is
commonly used as the di-electric fluid.
165. The di-electric fluid gets ionizes in between _____ gap.

a) tool-electrode
b) cathode-anode
c) workpiece-electrode
d) tool-workpiece
31

Answer: a
Explanation: The di-electric fluid gets ionized in between the tool-electrode gap and hence,
helps in creating a path for each discharge. Because of these discharges, material is
removed from the workpiece.
166. The burr or cut particles are flushed away by the______

a) electrode
b) motion of the workpiece
c) di-electric fluid
d) coolant
M
Answer: c
Explanation: The area wherein discharge takes place gets heated to very high temperatures
such that the surface gets melted and removed. The cut particles (debris) get flushed away
O
by the continuously flowing dielectric fluid.
C
167. Wire-cut EDM (WEDM) process is widely used for _____
a) alloy steels
T.
b) tool steels
c) stainless steels
O
d) carbon steels
Answer: b
SP
Explanation: WEDM is a non-conventional process and is very widely used in tool steels for
a pattern and die making industries. The process is also used for cutting intricate shapes in
components used for the electric and aerospace industries.
G
168. For which of the following materials wire-cut EDM is not used?
LO
a) Aluminium
b) Zirconium
c) Steels
d) Titanium
.B
Answer: b
17
Explanation: Wire-cut EDM is used for cutting:

• Aluminium
• Brass
• Copper
-R
• Graphite
• Steels
• Titanium.
SE
169. WEDM process can be used for cutting hard extrusion dies.
a) True
C
b) False
Answer: a
Explanation: This process is used in the following areas:
• Aerospace, Medical, Electronics and Semiconductor applications
• Tool & Die making industries.
• For cutting the hard Extrusion Dies
• In making Fixtures, Gauges & Cams.
32

170. WEDM process can be used for manufacturing of micro-tools.

a) True
b) False
Answer: a
Explanation: Following are the few areas where WEDM process is used:
• Cutting of Gears, Strippers, Punches and Dies
• Manufacturing hard Electrodes
• Manufacturing micro-tooling for Micro-EDM, Micro-USM and such other micromachining
applications.
M
171. How many subsystems are there in wire-cut EDM process?
a) 2
b) 3
O
c) 4
d) 5
C
Answer: c
T.
Explanation: The subsystems of Wire-EDM process are:
• Power supply
• Di-electric system
O
• Wire feeding system
• Positioning system.
SP
172. Di-electric system used in WEDM process is similar to that of the _____ process.
a) conventional drilling
G
b) conventional milling
c) conventional EDM
LO
d) broaching
Answer: c
Explanation: The power supply and the di-electric system used in WEDM is very similar to
.B
that of the conventional EDM. The main difference lies only in the type of di-electric used.
17
173. In wire-cut EDM, a moving wire is used to _____

a) remove the burr
b) cut complex outlines
c) melt the material
-R
d) make the way for the di-electric fluid
Answer: b
SE
Explanation: In wire-cut EDM, a moving wire is used to cut complex outlines and fine details
in the required workpiece. The wire is wound on a spool and is kept in constant tension
C
174. Wire electric discharge (ED) machining is based on the same principle as that of
_____
a) hydro-dynamic EDM
b) die-sink EDM
c) polar EDM
d) non-conventional EDM
Answer: b
Explanation: Wire electric discharge (ED) machining is based on the same principle as die-
33

sink ED machining. The basic elements in all EDM methods are dielectric fluid, a workpiece
and an electrode.
175. The only difference between die-sink EDM and wire cut EDM is the _____
a) way of material removal
b) electrode used for the machining
c) type of materials machined
d) processing time
Answer: b
Explanation: In the die-sink EDM method the electrode has the same shapes as the wished
M
machining results. In the wire cut EDM method the electrode is a moving wire made from
some electrically conducting material. The workpiece is cut with the electrode wire.
O
176. During wire cut EDM, the size of the cavity produced by the wire while machining
depends upon _____
C
a) material of the workpiece
b) di-electric fluid used
T.
c) wire material
d) electric current
O
Answer: d SP
Explanation: While machining a high electric current passes through the dielectric fluid and
heats the workpiece surface from a very small area. The corresponding workpiece area
melts and what is left, is a small round cavity. The cavity size depends on the electric current
and potential.
G
177. Sparking gap is the distance between _____

LO
a) the workpiece and the CNC table

b) the workpiece and the electrode wire
c) the electrode wire and the di-electric fluid
d) the workpiece and the spark plug
.B
Answer: b
17
Explanation: The distance between the electrode wire and the workpiece is called a sparking
gap. The electrode produces shapes that are a sparking gap dimension larger than the
programmed shape through which the electrode wire passes.
-R
178. The absolute minimum inner corner radius is _____

a) the wire radius minus the sparking gap width
b) the sparking gap width minus the wire radius
SE
c) the wire radius plus the sparking gap width

d) double of the wire radius
C
Answer: c
Explanation: The absolute minimum inner corner radius is the wire radius added with the
sparking gap width. Therefore during machining, the shapes produced have larger
dimensions as compared to the shapes mentioned in the program.
179. The wire ED machines have _____ programmable axes.

a) 2
b) 2-5
c) 6
d) 3-9
34

Answer: b
Explanation: The wire cut EDM machines have 2 – 5 programmable axes. The machines
that are used in mould making applications typically have 5 programmable axes. These axes
are Wire guide, wire tilting in x and y –directions and workpiece or wire system movements
in x and y –directions.
180. Which of the following component of the wire cut EDM machine does not get heated?
a) Workpiece
b) Electrode wire
c) Di-electric fluid
d) Coils
M
Answer: b
Explanation: The electrode wire moves between two coils with a moderate speed. The part
O
of the wire that actually machines the workpiece is constantly changing. There is no time for
the wire to heat up.
C
181. Which of the following material properties sets restrictions to use wire cut EDM?
T.
a) Material type
b) Melting point
O
c) Material hardness
d) Electrical conductivity SP
Answer: d
Explanation: As the electrode wire does not get heated during machining, the problems with
electrode wear are not an issue like in the case of die-sink ED machining and it is possible to
G
use wire cut EDM also for materials with high melting ranges. The material hardness sets no
restrictions. The only restriction is that the material needs to be electrically conductive.
LO
182. Wires used in wire cut EDM are usually disposed after one usage.
a) True
b) False
.B
Answer: a
17
Explanation: Despite the minimum wear, wires are usually disposed after one usage.
Sparking and high temperature during the machining reduces the wire tensile strength and
the wire could easily break if re-used.
-R
183. The electrode wires are usually made form _____

a) graphite
b) iron
SE
c) nickel
d) brass
C
Answer: d
Explanation: Wire used in wire cut EDM are usually made of brass – either zinc-coated or
uncoated. Brass wire can be purchased in different hardnesses and different diameters. Zinc
coated wire is used in machining high melting point workpiece materials
184. _____ grades wire are used in automatic re-threading mechanisms.

a) Malleable
b) Softer
c) Harder
35

d) Commercial
Answer: c
Explanation: The harder grades are used in automatic re-threading mechanisms and also if
the machined shapes contain high flat surfaces. Hard wires resist change in direction and for
that reason are likely to produce nice flat surfaces.
185. For machining of high melting point materials, _____ wires are used.
a) gallium
b) zinc coated
c) aluminium coated
M
d) silver
Answer: b
O
Explanation: Zinc coated wire is used in machining high melting point workpiece materials.
The zinc coating vaporises in lower temperature than the brass core. Vaporisation reduces
C
the amount of heat that transmits to the brass and the core wears less.
T.
186. _____ is/are used as di-electric fluid in die sink EDM process.
a) Pure water
O
b) Silicone gel
c) Petroleum products SP
d) Epoxy resins
Answer: c
Explanation: The dielectric fluid in the die-sink EDM process is usually some petroleum
G
product. In the wire cut EDM process, it is most common to use de-ionised water.
LO
187. Which of the following is not the application of wire cut EDM process?
a) Machining ejector holes
b) Cutting the ejector pins
c) Machining cores of various moulds
.B
d) Machining of complex shapes made of plastic

17
Answer: d
Explanation: The most typical wire cut EDM applications in mould making are: −
• Machining ejector holes
• Shaping and cutting the ejector pin ends to follow mould cavity surface shapes
-R
• Machining cores and corresponding fastening holes in the mould plates and inserts.
188. During mould making by wire cut EDM, it is important to harden ______ to counter the
SE
effects of changes in the shape of the workpiece due to heat treatment.

a) the insert
b) electrode wire
C
c) electrode holding coils

d) bolting points in the workpiece
Answer: a
Explanation: It is important to harden the insert or mould plate steel before making the tightly
tolerated ends in the ejector pin holes because the heat treatment tends to change the
workpiece shapes at a certain degree.
189. Which of the following machining process is usually preferred for cutting of ejectors
which are used in mould making?
a) Milling
36

b) Hobbing
c) Wire-cut EDM
d) Die sink EDM
Answer: c
Explanation: There is a need to cut the ejector to a right dimension and if the cavity surface
is shaped there is also a need to shape the ejector end. The wire ED machine is one of the
most accurate machines in mould shops and usually there is also free machining time
available. Another option is to cut and shape the ejectors in a milling machine, but the most
accurate milling machines are used in mould cavity machining operations and normally they
are rather busy for long periods of time.
M
190. How many ways are there for making the fixed cores by wire cut EDM process?
a) 2
O
b) 3
c) 4
C
d) 5
T.
Answer: a
Explanation: Basically there are two options for making the fixed cores:
− Machine the cores directly to the mould insert plate or mould plate
O
− Machine the cores to separate pieces of mould steel and attach the piece to the mould
SP
assembly.
191. The selection of the manufacturing process depends upon ____________

a) chemical reactivity between the mould material and the di-electric fluid
G
b) mould shape
c) application of the mould
LO
d) number of parts to be machined
Answer: b
Explanation: The selection depends on the core dimensions and shapes. High and narrow
.B
cores or cores with sharp shapes are easiest to manufacture with separate parts. Special
cases are core pins. Core pins are used in making small diameter holes to castings.
17
192. The wire EDM process is used for making moulds with high drafted walls.
a) True
b) False
-R
Answer: a
Explanation: Like every wall in the mould opening direction, the core walls are also drafted. It
SE
is rather difficult to make high drafted walls with a milling machine. Especially in the case of
injection moulding or high pressure die casting moulds where the accuracy requirements are
very high. The wire ED machine produces these shapes accurately with ease.
C
193. For manufacturing of complex shapes, soft electrode wires are used.
a) True
b) False
Answer: a
Explanation: Soft wires are useful in applications with complex shapes, where the machine
changes the wire tilting angle several times. The harder grades are used in automatic re-
threading mechanisms
37

Laser Beam Machining (LBM)
Laser Beam Machining-Introduction

194. What is the full form of LBM in advanced machining processes?
a) Laser Beam Manufacturing
b) Laser Beam Machining
c) Light Blast Manufacturing
d) Light Beam Machining
Answer: b
M
Explanation: The full form of LBM is Laser Beam Machining in the advanced machining
processes.
O
195. LBM offers a good solution for which material properties below?
a) Thermal conductivity
C
b) Specific heat
c) Boiling temperature
T.
O
Answer: d
Explanation: LBM offers good solution for material properties such as thermal conductivity,
SP
specific heat, melting and boiling temperatures.
196. What is the abbreviation of Laser?

a) Light allowed simple emission of radiation
G
b) Light amplification by stimulated emission of radiation

c) Light amplified simultaneous emission of rays
LO
d) Light amplified stimulated emanation of rays
Answer: b
Explanation: Full form of laser is Light Amplification by Stimulated emission of radiation.
.B
197. Which of the following are the properties of a laser?

17
a) Highly collimated
b) Monochromatic
c) Coherent light beam
-R
Answer: d
Explanation: Highly collimated, high monochromaticity and the coherence of the light beam
SE
are the properties of a laser.
198. Laser beam machining uses which type of power sources for machining?
C
a) Very low power

b) Low power
c) Medium power
d) High power
Answer: d
Explanation: High power densities are used for the generation of laser and for machining in
Laser beam machining.
199. Which of the following are different types of lasers used in Laser beam machining?
a) Solid-state ion
38

b) Neutral gas
c) Semiconductor
Answer: d
Explanation: Laser such as solid-state ion, neutral gas, molecular, semiconductor etc.., can
be used in LBM.
200. Which types of lasers are used in Laser beam machining?

a) Continuous wave
b) Pulsed mode
M
c) Continuous wave & Pulsed mode
O
Answer: c
Explanation: Laser may be in continuous wave (CW) or in Pulsed mode (PM) for machining
C
in LBM.
T.
201. What is the wavelength value of Ruby laser used in Laser beam machining?
a) 633 nm
O
b) 694 nm
c) 856 nm SP
d) 1064 nm
Answer: b
Explanation: The value of wave length of Ruby laser used in Laser Beam machining is 694
G
nm.
LO
202. What is the wavelength value of Nd-YAG and Nd-glass lasers used in LBM?
a) 633 nm
b) 694 nm
c) 856 nm
.B
d) 1064 nm
17
Answer: d
Explanation: The value of wave length of Nd-YAG and Nd-glass lasers used in LBM is 1064
nm.
-R
203. What is the wavelength value of neutral gas laser used in LBM?
a) 633 nm
b) 694 nm
SE
c) 856 nm
d) 1064 nm
C
Answer: a
Explanation: The value of wave length of Neutral gas laser used in Laser beam machining is
633 nm.
204. What is the wavelength value of CO2 laser used in Laser beam machining?
a) 0.16 μm
b) 1.6 μm
c) 10.6 μm
d) 106 μm
39

Answer: c
Explanation: The value of wave length of CO2 laser used in Laser Beam machining is 10.6
μm.
205. What are the values of wavelengths of GaAs laser used in LBM?
a) 100 – 200 nm
b) 200 – 400 nm
c) 600 – 700 nm
d) 800 – 900 nm
Answer: d
Explanation: The wavelengths of GaAs laser used in LBM range from 800 – 900 nm.
M
206. What are the values of wavelengths of Excimer laser used in LBM?
O
a) 100 – 200 nm
b) 200 – 500 nm
C
c) 600 – 700 nm
d) 800 – 900 nm
T.
Answer: b
Explanation: The wavelengths of Excimer laser used in LBM range from 200 – 500 nm.
O
14. What are the values of wavelengths of Argon laser used in LBM?
a) 120 – 230 nm
SP
b) 220 – 310 nm
c) 330 – 530 nm
d) 760 – 940 nm
G
Answer: c
LO
Explanation: The wavelengths of Argon laser used in LBM range from 330 – 530 nm
LBM-Material Removal
.B
207. What is the material removal mechanism of Laser beam machining process?
a) Melt and evaporate
b) Electro chemical corrosion
17
c) Mechanical erosion of materials

d) Electro chemical dissolution
-R
Answer: a
Explanation: The material is removed by melting and evaporation in Laser Beam Machining
process.
SE
208. Physics of laser is very complex due to which of the reasons below?
a) Scattering loss
b) Reflection loss
C
c) Scattering & Reflection loss

Answer: c
Explanation: Physics of laser is very complex because of scattering and reflection losses.
209. What happens when the heat is diffused into bulk material?
a) Phase change occurs
b) Melting occurs
c) Vaporization may take place
40

Answer: d
Explanation: The heat diffusion into bulk material causes phase change, melting or
vaporization in the materials.
210. State whether the following statement is true of false regarding LBM.
“In LBM, high intensity laser beams are recommended for more material.”
a) True
b) False
M
Answer: b
Explanation: High intensity laser beams are not recommended since they form a plasma
plume near surface of material.
O
211. What happens to the process efficiency if plasma plumes are formed in LBM?
C
a) Increases
b) Enhances
T.
c) Decreases
d) Improves
O
Answer: c SP
Explanation: In Laser beam machining, the process efficiency is reduced due the absorption
and scattering loses when plasma plumes are formed.
212. Machining of LBM takes place when power density is ____________ than what is lost
G
by conduction and radiation.
a) Greater
LO
b) Smaller
c) Lower
d) Same as
.B
Answer: a
Explanation: Machining of laser takes place when power density is greater than what is lost
17
by conduction, convection and radiation.
213. Which of the following phenomenon take place before melting and evaporating in
LBM?
-R
a) Conduction
b) Reflection
c) Absorption
SE
Answer: d
C
Explanation: Material in LBM is removed through several effects such as conduction,

absorption, reflection following melting and evaporation.
214. What happens to the material removal rate when reflectivity is higher?
a) Will decrease
b) Will increase
c) Will enhance
d) Remains same
41

Answer: a
Explanation: In LBM, as the reflectivity of the metals is increased the material removal rates
of the process are decreased.
215. Reflectivity of the materials depends on which of the following factors?

a) Wave length
b) Properties of material
c) Surface finish
Answer: d
M
Explanation: Reflectivity of the materials depends on wavelength, the properties of materials,
surface finish and temperature.
O
216. How much amount of incident radiation is reflected at lower power densities?
a) 10 percent
C
b) 20 percent
c) 50 percent
T.
d) 90 percent
O
Answer: d
Explanation: Most of the metals reflect nearly 90 percent of incident radiation if the power
SP
densities are low.
217. How are minimum energies required for plastics when compared to that required for
metals?
G
a) Lower than
b) Higher than
LO
c) Same as
Answer: a
.B
Explanation: The minimum energies required for plastic are lower than that required for
metals.
17
218. Which of the following has high machining speeds in Laser Beam Machining?
a) Metals
b) Non metals
-R
c) Metal alloys
SE
Answer: b
Explanation: Non metallic material machine at higher speeds than metallic ones due to
higher reflectivity in metallic materials
C
LBM-Applications
219. Which of the following are the applications of Laser Beam Machining?
a) Drilling
b) Cutting
c) Texturing
42

Answer: d
Explanation: Drilling, cutting and grooving, texturing and structuring, milling and dressing
etc.., are the applications of Laser beam machining process.
220. State whether the following statement is true or false regarding the drilling using LBM.
“Compared to LBM, conventional machining is more accurate and efficient.”
a) True
b) False
Answer: b
Explanation: Conventional machining is less sufficient than Laser Beam machining because
M
of their material toughness.
221. Other non-conventional processes lay behind Laser beam machining in drilling
O
process because of which factors below?
a) High cost
C
b) Long lead times
c) Low machining speeds
T.
O
Answer: d
Explanation: Other non-conventional processes need high costs for tools, long lead times,
SP
and low machining speeds when compared to LBM.
222. Laser drilling has proven to be more efficient in which of the following factors?
a) Cost
G
b) Quality
c) Reliability
LO
Answer: d
Explanation: Laser drilling has proven to be an efficient one in terms of cost, quality, and
.B
reliability for large-scale production applications.

17
223. Which of the following are different laser drilling processes in Laser beam machining?
a) Direct drilling
b) Drill and ream
c) Trepanning
-R
Answer: d
SE
Explanation: Laser drilling can be performed by three methods that are – direct (percussion)
drilling, trepanning, drill and ream.
C
224. The hole size in direct drilling depend up on which of the factors below?
a) Input power
b) Focusing adjustments
c) Input power & Focusing adjustments
Answer: c
Explanation: The hole size in the direct drilling method of Laser drilling process, depend on
input power and focusing adjustments.
43

225. Which method mentioned below is used for drilling of large size holes?
a) Direct drilling
b) Drill and ream
c) Trepanning
Answer: c
Explanation: Trepanning method of laser drilling process is used for drilling large holes either
by rotating or moving the part.
226. What are the values of diameters obtained by using Laser drilling process?
a) 0.0001 – 0.001 mm
M
b) 0.001 – 0.01 mm
c) 0.005 – 1.25 mm
O
d) 1.5 – 10.5 mm
C
Answer: c
Explanation: Values of diameters obtained by using Laser drilling process range between
T.
0.005 – 1.27 mm.
O
227. What is the value the maximum optimum depth that can be machined using Laser
drilling process? SP
a) 0.17 mm
b) 1.7 mm
c) 17.1 mm
d) 171.7 mm
G
Answer: b
LO
Explanation: The maximum depth obtained when by using laser drilling is about 1.7 mm.
228. What are the values of entrance angles that vary in Laser drilling process?
a) 0.1 – 1 oC
.B
b) 1 – 5 oC
c) 15 – 90 oC
17
d) 90 – 150 oC
Answer: c
Explanation: Values of the entrance angles in Laser drilling process range between 15 –
-R
90 oC.
229. The taper obtained in Laser drilling process is how much of the hole diameter?
SE
a) 1 – 5%
b) 5 – 20%
c) 20 – 50%
C
d) 50 – 90%
Answer: b
Explanation: Taper value obtained in Laser drilling process range between 5 – 20% of the
hole diameter.
230. What is the depth-to-diameter ratio obtained in drilling process using Laser beam
machining?
a) 10:1
b) 20:1
c) 50:1
44

d) 80:1
Answer: c
Explanation: Value of the maximum depth-to-diameter ratio obtained in drilling using Laser
beam machining is 50:1.
231. What is the maximum value of drilling depth in trepanning method of laser drilling
process?
a) 1.7 mm
b) 4.3 mm
c) 6.4 mm
M
d) 7.9 mm
Answer: c
O
Explanation: The depth increases when we use a trepanning method for laser drilling
process and that is about 6.40 mm.
C
232. What are the tolerance values obtained when we use laser drilling process?
T.
a) 0.1 – 5%
b) 5 – 20%
c) 25 – 50%
O
d) 50 – 80% SP
Answer: b
Explanation: The tolerance values are will range between 5 – 20% of the diameters obtained
in Laser drilling process.
G
233. What is the value of minimum corner radius obtained by drilling in Laser beam
LO
machining?
a) 0.10 mm
b) 0.25 mm
c) 0.50 mm
.B
d) 0.65 mm
17
Answer: b
Explanation: The value of the minimum corner radius obtained while drilling using LBM is
about 0.25 mm
-R
234. Peak power should be increased in Laser drilling process by __________ pulse
energy.
a) Increasing
SE
b) Decreasing
c) Reducing
d) Constant
C
Answer: a
Explanation: Required peak power in the laser drilling process can be obtained by increasing
the pulse energy while keeping the pulse duration constant.
235. Drilling of holes with larger pulse duration causes which effect to the holes produced?
a) Enlarge holes
b) Reduce hole size
c) Decrease the depth
45

Answer: a
Explanation: Drilling the holes with larger pulse duration causes enlargement of the hole
entrance.
236. What are pulse duration values used for laser drilling?
a) 0.01 to 0.25 ms
b) 0.1 to 2.5 ms
c) 1 to 25 ms
d) 10 to 250 ms
Answer: b
M
Explanation: Value of the duration of the pulse range from 0.1 to 2.5 ms.
237. _________ pulse energy and _________ pulse duration are suitable for drilling.
O
a) Low, short
b) Low, long
C
c) High, short
d) High, long
T.
Answer: c
O
Explanation: In LBM, high energy pulses and low pulse duration are more suitable for hole
drilling in aerospace materials. SP
238. Which of the following are the functions of assist gases?
a) Removal of molten material
b) Shield the lenses
G
c) Better efficiency
LO
Answer: d
Explanation: Assist are used to remove the molten material, it also shield the lenses from
expelled material and they are also used for obtaining better process efficiencies.
.B
239. Selection of assist gas depends on which of the following properties of work piece?
17
a) Material
b) Thickness
c) Material & Thickness
-R
Answer: c
Explanation: The selection of different assist gases depends on the work piece material and
SE
its thickness.
240. Which of the following properties of material affect the quality of holes obtained?
C
a) Reflectivity
b) Absorption coefficient
c) Thermal conductivity
Answer: d
Explanation: Quality of holes depend on reflectivity, absorption coefficient, thermal
conductivity, density, specific heat, and latent heat of material.
241. What range of powers are used for cutting through steel?
a) 1 to 20 W
46

b) 20 to 100 W
c) 200 to 1000 W
d) 1 to 20 kW
Answer: c
Explanation: The power ranges from 200 W to 1 kW for cutting through steel.
242. Which gas jet assisted process is suitable for most of the metals?
a) Oxygen gas
b) Nitrogen gas
c) Helium gas
M
Answer: a
O
Explanation: Oxygen-jet assistance is used for most metals, as the gas liberates additional
energy by the exothermal chemical reactions.
C
243. What happens to the cutting speed with an increase in the work piece?
T.
a) Increases
b) Decreases
O
c) Enhances
d) Remains same SP
Answer: b
Explanation: The cutting speed of the process of drilling decreases with an increase in the
thickness of the work piece material.
G
244. What is the full form of LBT in the processes of LBM?

LO
a) Laser Beam Tempering

b) Laser Beam Templating
c) Laser Beam Texturing
d) Laser Beam Tinning
.B
Answer: c
17
Explanation: Full form of LBT is Laser beam texturing which is an application of Laser beam
machining.
245. Depth and the crater size depends on which of them below?
-R
a) Energy of beam
b) Dwell time of beam
c) Energy & Dwell time of beam
SE
Answer: c
C
Explanation: Depth and the crater size depend on the energy and the dwell time of beam.
246. Where are the textured surfaces used that are obtained in LBT?
a) Mould makings
b) Bearings
c) Printer roll manufacturing
Answer: d
Explanation: Textured surfaces obtained in LBT are widely used in mold making, bearings
and printer roll manufacturing.
47

247. The roll is _________ and the laser beam is moved ________ along the roll.
a) Stationary, axially
b) Stationary, perpendicularly
c) Rotated, axially
d) Rotated, perpendicularly
Answer: c
Explanation: In texturing process of LBT, the roll is rotated and laser is moved axially along
the roll.
248. State whether the following statement is true regarding the texturing in LBT.
“In LBT, hardness of the material is a limitation to the process.”
M
a) True
b) False
O
Answer: b
C
Explanation: In Laser beam texturing, hardness of material is not a limitation to the process
T.
249. Which of the following are the other applications of LBM?
a) Dressing of grinding wheels
O
b) Scribing
c) Micromachining
SP
Answer: d
Explanation: Dressing of grinding wheels, scribing, micromachining, controlled fracturing are
G
some of the other applications of Laser beam machining.

LO
250. How the grooves in grinding wheels are produced using laser?
a) Evaporation
b) Damage of composite
.B
c) Evaporation & Damage of composite

17
Answer: c
Explanation: Grooves on the grinding wheels are produced due to evaporation and damage
of the composite wheel material.
-R
251. Work piece tilting depends on which of the following factors?

a) Incident power
SE
b) Beam speed
c) Groove direction
C
Answer: d
Explanation: Work piece tilting depends on the incident power, beam speed, groove
direction, and optical absorption coefficient of the material.
252. What are the values of thickness used is fine cutting process?
a) 0.01 to 0.05 mm
b) 0.05 to 0.1 mm
c) 0.5 to 15 mm
d) 15 to 50 mm
48

Answer: c
Explanation: The thickness of material used in fine cutting process vary from 0.5 to 16 mm.
253. The advantages of excimer laser are due to __________ laser wavelength and
_________ pulse duration.
a) Short, short
b) Short, long
c) Long, short
d) Long, long
Answer: a
M
Explanation: The practical advantages of excimer laser are mainly due to short laser
wavelength and pulse duration.
O
254. Lasers of which type are used for modification of electronic components?
a) High power
C
b) Small spot size
c) Short pulse length
T.
O
Answer: d
Explanation: Lasers of high power density, small spot size and short pulse length are useful
SP
devices for modification of electronic components.
255. Material removal rates which are about mg/pulse produces which type of holes?
a) Shallow
G
b) Deep
c) Very deep
LO
Answer: a
Explanation: In LBM, material removal at the rate of milligrams per pulse produces shallow
.B
holes in the material.

17
256. Which of the following materials can be easily separated by laser scribing?
a) Silicon
b) Glass
c) Ceramic
-R
Answer: d
SE
Explanation: Brittle materials such as silicon, glass and ceramics may be effectively shaped
or separated by laser scribing.
C
257. Which type of holes can be drilled using Nd-YAG laser?

a) Small holes
b) Large holes
c) Small & Large holes
Answer: c
Explanation: Nd-YAG laser can be used for drilling small holes as well as large holes by
trepanning process.
49

258. Which type of laser can be used for direct drilling or percussion?
a) Ruby laser
b) Nd-YAG laser
c) Ruby & Nd-YAG laser
Answer: c
Explanation: Both Ruby and Nd-YAG laser can be used for direct (percussion) drilling
purpose.
259. Which of the following lasers is used for cutting thick materials in LBM?
M
a) CO2 + gas assisted
b) CO2 only
c) Nd-YAG
O
d) Ruby
C
Answer: a
Explanation: CO2 + gas assisted laser is used for cutting thicker materials in Laser beam
T.
machining process.
O
260. Which of the following lasers is used for slitting of thin metallic materials in LBM?
a) CO2 + gas assisted SP
b) CO2 only
c) Nd-YAG
d) Ruby
G
Answer: c
Explanation: Nd-YAG laser is used for slitting of thin metallic materials in Laser beam
LO
machining process.
261. Which of the following lasers is used for slitting of thin plastic materials in LBM?
.B
b) CO2 only
c) Nd-YAG
17
d) Ruby
Answer: b
Explanation: CO2 laser is used for slitting of thin plastic materials in Laser beam machining
-R
process.
262. Which of the following lasers is used for organics and non-metallic materials in LBM?
SE

b) Pulsed CO2
c) Nd-YAG
C
d) Ruby
Answer: b
Explanation: Pulsed CO2 laser is used for organics and non-metallic materials in Laser beam
machining process.
263. Which of the following lasers is used for ceramic materials in LBM?
a) Pulsed CO2
b) Nd-YAG
c) Pulsed CO2 & Nd-YAG
50

Answer: c
Explanation: Both pulsed CO2 and Nd-YAG lasers can be used for ceramic materials in LBM
LBM-Advantages and Limitations

264. Which of the following is not an advantage of LBM?
a) Rapid machining
b) Low operating cost
c) High equipment cost
d) No tool wear
M
Answer: c
O
Explanation: Rapid machining, low operating cost and no tool wear are some of the
advantages of Laser beam machining.
C
265. Which of the following systems is used for locating the hole accurately for alignment?
T.
a) Mechanical control system
b) Optical laser system
c) Measurement system
O
d) Alignment system SP
Answer: b
Explanation: Holes can be accurately located using optical laser system for alignment in
Laser beam machining.
G
266. Very __________ holes with a ________ aspect ratio can be produced using Laser
LO
beam machining.
a) Small, small
b) Small, large
c) Large, small
.B
d) Large, large
Answer: b
17
Explanation: In Laser beam machining, very small holes with large aspect ratios can be
produced.
-R
267. How are the machining times in Laser beam machining?

a) Very slow machining times
b) Slow machining times
SE
c) Moderate machining times

d) Fast machining times
Answer: d
C
Explanation: Machining is very much rapid and the setup times are economical in Laser
beam machining.
268. How is the operating cost of the machines used in Laser beam machining?
a) Low
b) Moderate
c) High
d) Very high
51

Answer: a
Explanation: The operating cost of the machines in LBM is low but the equipment cost itself
is of high cost.
269. State whether the following statement is true or false regarding the advantages of
LBM.
“In LBM, difficult to cut machine material can also be machined.”
a) True
b) False
Answer: a
M
Explanation: A large variety of hard and difficult to cut materials can be machined using
LBM.
O
270. How much amount of tapers are occurred in Laser drilled holes?
a) No taper
C
b) Negligible amount of taper
c) Some amount
T.
O
Answer: c
Explanation: Tapers are generally occurred in the direct drilling of holes using Laser beam
SP
machining.
271. State whether the following statement regarding Laser beam machining is true or false.
“In LBM, a blind hole of precise depth is easy to achieve.”
G
a) True
b) False
LO
Answer: b
Explanation: A blind hole of precise is difficult to achieve in Laser beam machining.
.B
272. What is the maximum depth up to which holes can be drilled using LBM?
a) 10 mm
17
b) 30 mm
c) 50 mm
d) 70 mm
-R
Answer: c
Explanation: The thickness of the material that can be laser drilled is restricted to 50 mm.
SE
273. What is to be done to the adherent material which are found at exit holes?
a) Shape them
b) Leave away
C
c) Remove them
d) Flatten them
View Answer
Answer: c
Explanation: Adherent material found at the exit of holes has to be removed in LBM
Plasma Arc Machining (PAM) / Plasma Beam Machining

Plasma Beam Machining-Introduction And Machining system
52

274. What is the full form of PBM in the advanced machining processes?
a) Plasma Beam Manufacturing
b) Plasma Beam Machining
c) Plasma Blast Manufacturing
d) Plasma Blast Machining
Answer: b
Explanation: The full form of PBM in the advanced machining processes is Plasma Beam
Machining.
275. When the Plasma Beam machining process came into the industrial world?
M
a) 1920s
b) 1930s
c) 1950s
O
d) 1970s
C
Answer: c
Explanation: The Plasma Beam machining process came into the industrial world in the early
T.
1950s as an alternative for the oxy-gas flame cutting process.
O
276. PBM is the only process which works faster in ________ steel than _________ steel.
a) Stainless, mild SP
b) Mild, stainless
c) Remains same all
G
Answer: a
Explanation: PBM is the only fabrication process which works faster in stainless steels
LO
compared to mild steels.
277. What is the temperature reached by cathode in order to produce plasma beam?
a) 12000 ºC
.B
b) 18000 ºC
c) 28000 ºC
17
d) 40000 ºC
Answer: c
Explanation: The temperature reached by cathode to produce plasma arc is about 28000 ºC
-R
in Plasma Beam Machining.
278. What is the value of velocity of plasma jet in Plasma beam machining?
SE
a) 100 m/sec
b) 300 m/sec
c) 400 m/sec
C
d) 500 m/sec
Answer: d
Explanation: The value of the velocity of the plasma jet in Plasma beam machining is about
500 m/sec.
279. What is the value of material removal rate in Plasma Beam Machining process?
a) 50 cm3/min
b) 100 cm3/min
c) 150 cm3/min
53

d) 200 cm3/min
Answer: c
Explanation: The values of the material removal rates in Plasma beam machining will be
nearly 150 cm3/min.
280. What is the value of specific energy used in Plasma beam machining process?
a) 100 W/(cm3-min)
b) 200 W/(cm3-min)
c) 300 W/(cm3-min)
d) 400 W/(cm3-min)
M
Answer: a
Explanation: The value of the specific energy used in Plasma beam machining process is
O
about 100 W/(cm3-min).
C
281. What is the value of the power used in PBM process?
a) 0.1 – 10 kW
T.
b) 2 – 200 kW
c) 200 – 400 kW
d) 400 – 700 kW
O
Answer: b
SP
Explanation: The value of the power used in Plasma beam machining range from 2 to 200
kW.
G
282. What is the value of the voltage used in PBM process?
a) 0.1 – 20 V
LO
b) 30 – 250 V
c) 300 – 400 V
d) 500 – 600 V
.B
Answer: b
Explanation: The value of voltage in the Plasma beam machining processes is about 30 –
17
250 V.
283. What is the value of the current used in PBM process?

a) Up to 200 A
-R
b) Up to 400 A
c) Up to 600 A
d) Up to 800 A
SE
Answer: c
Explanation: The value of the current used in PBM will be up to 600 A.
C
284. What is the value of machining speed used in PBM process?

a) 0.1 – 7.5 m/min
b) 8.5 – 10.5 m/min
c) 15.5 – 19.5 m/min
d) 20.5 – 25.5 m/min
Answer: a
Explanation: The value of machining speed is about 0.1 – 7.5 m/min in Plasma beam
machining process.
54

285. What is the maximum value of the thickness used in PBM process?
a) 100 mm
b) 200 mm
c) 300 mm
d) 400 mm
Answer: b
Explanation: The maximum value of the thickness used in the Plasma beam machining
process is about 200 mm.
286. Which of the following are the different shielded plasmas used in PBM?
M
a) Gas-shielded plasma
b) Water-shielded plasma
c) Gas-shielded & Water-shielded plasma
O
C
Answer: c
Explanation: Both gas-shielded plasma and water shielded plasma are used in the Plasma
T.
beam machining process
O
PBM – MRR, Surface Quality, Applications, Advantages and
Disadvantages
SP
287. Material removal rates depend on which of the following factors?
b) Type of cutting
G
c) Shielding gases
LO
Answer: d
Explanation: Material removal rates in PBM depend on work piece material, type of cutting
and the shielding gas.
.B
288. A low power factors indicates __________ energy required and __________ removal
17
rates.
a) Low, low
b) Low, high
c) High, low
-R
d) High, high
Answer: b
SE
Explanation: A low power factor in Plasma beam machining indicates low energy required
and high material removal rates.
C
289. What happens to the machining speed if the thickness of material is increased in
PBM?
a) Decreases
b) Increases
c) Enhanced
d) Remains same
Answer: a
Explanation: Machining speed in Plasma beam machining reduces with an increase in the
thickness of the work piece material.
55

290. What is the machining speed required for machining of 12mm thick plate with 220 kW
energy?
a) 1000 mm/min
b) 1500 mm/min
c) 2000 mm/min
d) 2500mm/min
Answer: d
Explanation: Machining speed required for cutting 12-mm thick plate with 220 kW power is
about 2500 mm/min.
M
291. How much distortion is produced while machining using PBM?
a) 10%
b) 20%
O
c) 30%
d) No distortion is produced
C
Answer: d
T.
Explanation: Heat does not penetrate more than few microns from the edges of the cuts
produced by machining using PBM that produce no distortion.
O
292. The cut edge of the material tends to be __________ than the base metal in PBM.
SP
a) Smoother
b) Harder
c) Same as
G
Answer: b
LO
Explanation: The cut edge of material in PBM tends to be harder than the base metal.
293. What is the thickness of the HAZ in PBM?

a) 0.001 to 0.23 mm
.B
b) 0.25 to 1.12 mm
c) 1.3 to 2.56 mm
17
d) 2.73 to 5.26 mm
Answer: b
Explanation: The thickness of the HAZ obtained in PBM range from 0.25 to 1.12 mm.
-R
294. How much thickness of cracks may arise beyond HAZ due to rapid cooling?
a) 1.6 mm
SE
b) 2.6 mm
c) 3.6 mm
d) 4.6 mm
C
Answer: a
Explanation: The cracks due to rapid cooling in PBM may extend beyond HAZ to a thickness
of 1.6 mm.
295. What are the values of tolerances obtained by using PBM?

a) ± 0.6 mm
b) ± 1.6 mm
c) ± 2.6 mm
d) ± 3.6 mm
56

Answer: b
Explanation: The values of the tolerances obtained by using Plasma beam machining will be
about ± 1.6 mm.
296. What is the maximum thickness of the walls of tube machined using plasma arc?
a) 10 mm
b) 30 mm
c) 50 mm
d) 70 mm
Answer: c
M
Explanation: The maximum thickness of the wall tubes that can be produced using PBM is
about 50 mm.
O
297. Which of the following are the advantages of PBM?
a) No chemical
C
b) Less harmful
c) Operates cleanly
T.
O
Answer: d
Explanation: Main advantages of Plasma bema machining are no complicated chemical
SP
analysis, less harmful and no harmful exposure and it operates cleanly.
298. Which of the following chemicals are used in PBM?

a) Harmful chlorinated fluorocarbons
G
b) Acid cleaning chemicals
c) Dissolvable solvent chemicals
LO
Answer: d
Explanation: Plasma beam machining uses no harmful chlorinated fluorocarbons, acid
.B
cleaning chemicals or any dissolvable solvents.

17
299. How much amount of energy is required for machining using PBM?
a) Low
b) Moderate
c) High
-R
d) Very high
Answer: a
SE
Explanation: The cost for operating the jobs in Plasma beam machining is less and also less
energy is required for operating the machine in PBM.
C
300. What are the disadvantages of PBM?

a) Large power supplies
b) Heat produced
c) Toxic fumes produced
Answer: d
Explanation: Large power for more thick materials, production of heat and toxic fumes are
some of the main disadvantages of PBM
57

Electron Beam Machining (EBM)
Electron Beam Machining-Introduction, Equipment and Material

removal
301. What is the full form of EBM in the advanced machining processes?
a) Electro blast manufacturing
b) Electron beam machining
c) Electron beam manufacturing
d) Electron blast manufacturing
M
Answer: b
Explanation: The full form of EBM is Electron beam machining in the advanced machining
processes.
O
302. The prototype of the machine used in EBM process was first introduced in which year?
C
a) 1924
b) 1943
T.
c) 1947
d) 1956
O
Answer: c SP
Explanation: Steigerwald was the scientist who designed a prototype machine of electron
beam machining in 1947.
303. When did the Electron beam machining come into the machining industry?
G
a) 1920s
b) 1930s
LO
c) 1950s
d) 1960s
Answer: d
.B
Explanation: The Electron beam machining was introduced to the machining industry in the
early 1960s.
17
304. Which of the following are the applications of EBM process?

a) Drilling
b) Cutting
-R
c) Engraving
SE
Answer: d
Explanation: Drilling small holes, cutting, engraving, and heat treatment are some of modern
applications of Electron beam machining.
C
305. The tungsten filament cathode is heated to what temperatures in EBM?

a) 1000 to 1500 ᵒC
b) 1500 to 2000 ᵒC
c) 2500 to 3000 ᵒC
d) 3500 to 5000 ᵒC
Answer: c
Explanation: The tungsten filament cathode is heated to 2500 to 3000 ᵒC in Electron beam
machining.
58

306. What are the values of currents used in EBM process?

a) 1 and 20 mA
b) 20 and 100 mA
c) 100 and 200 mA
d) 200 and 400 mA
Answer: b
Explanation: The values of the currents used in the Electron beam machining process are
between 20 and 100 mA.
307. What are the values of current densities used in the process of EBM?
M
a) 5 and 15 A/cm2
b) 15 and 20 A/cm2
c) 20 and 30 A/cm2
O
d) 40 and 60 A/cm2
C
Answer: a
Explanation: The values of the current densities used in EBM lie between 5 and 15 A/cm 2.
T.
308. Emission current depends up on which of the following factors?
O
a) Cathode material
b) Temperature SP
c) Voltage supply
Answer: d
G
Explanation: Emission current depends on the cathode material, temperature, and the high
voltage in the process of Electron beam machining.
LO
309. What are the values of voltages used in the EBM process?
a) 10 V
b) 50 V
.B
c) 150 V
d) 200 V
17
Answer: c
Explanation: The values of voltages used in the process of electron beam machining is
about 150 V.
-R
310. Which of the following lenses are used for refocussing the electrons in EBM process?
a) Magnetic lens
SE
b) Electronic lens
c) Magnetic & Electronic lens
C
Answer: c
Explanation: Magnetic and electronic lenses are used to refocus the electrons in EBM
process.
311. What are the values of velocity maintained in the EBM process?
a) 118 x 103 m/s
b) 228 x 103 m/s
c) 338 x 103 m/s
d) 448 x 103 m/s
59

Answer: b
Explanation: The value of the velocity used in the process of electron beam machining is
about 228 x 103 m/s.
312. What are the values of power densities used in the EBM process?
a) 0.05 MW/mm2
b) 0.55 MW/mm2
c) 1.55 MW/mm2
d) 2.55 MW/mm2
Answer: c
M
Explanation: The value of the power densities used in the process of electron beam
machining are about 1.55 MW/mm2.
O
313. What is the frequency of the pulse of electrons used in EBM process?
a) 10 Hz
C
b) 102 Hz
c) 103 Hz
T.
d) 104 Hz
O
Answer: d
Explanation: A pulsed electron beam at 104 Hz reduces the temperature of the work piece
SP
outside the region being machined.
314. What are the values of material removal rates in EBM process?
a) 1 mm3/min
G
b) 10 mm3/min
c) 100 mm3/min
LO
d) 1000 mm3/min
Answer: b
Explanation: The values of the material removal rates in the process of electron beam
.B
machining are about 10 mm3/min.

15. What are the values of the cavity diameters that are obtained in EBM?
17
a) 15 to 20 µm
b) 20 to 25 µm
c) 30 to 35 µm
d) 35 to 40 µm
-R
Answer: d
Explanation: The values of the cavity diameters range from 35 to 40 µm
SE
EBM-Applications, Advantages and Disadvantages

315. Which of the following are the applications of EBM?
C
a) Hole drilling
b) Slotting
c) Perforation of thin sheets
Answer: d
Explanation: Drilling, perforation of thin sheets, slotting and integrated circuit fabrication are
some of the applications of Electron beam machining.
60

316. What is the value of largest diameter of the hole drilled on EBM?
a) 0.5 mm
b) 1.0 mm
c) 1.5 mm
d) 2.0 mm
Answer: c
Explanation: The maximum value of diameter that can be drilled using Electron beam
machining is about 1.5 mm.
317. What is the value of maximum depth of the hole drilled on EBM?
M
a) 10 mm
b) 20 mm
c) 30 mm
O
d) 40 mm
C
Answer: c
Explanation: Value of the maximum depth that can be drilled using Electron beam machining
T.
is about 10 mm.
O
318. What is the range of depth-to-diameter ratio in Electron beam machining?
a) 2:5 to 2:11 SP
b) 1:1 to 1:15
c) 3:4 to 3:20
d) 4:5 to 4:19
G
Answer: b
Explanation: The depth to diameter ratio in Electron beam machining will vary between 1:1
LO
and 1:15.
319. How many holes can be produced in perforation of thin sheets using EBM?
a) 101 to 102
.B
b) 102 to 103
c) 103 to 104
17
d) 104 to 105
Answer: d
Explanation: Number of holes produced range from 10 4 to 105 per second in perforation
-R
using EBM.
320. What is the value of energy required for bond breaking?

SE
a) 10 to 20kV
b) 20 to 30kV
c) 30 to 40kV
C
d) 40 to 50kV
Answer: a
Explanation: Value of the beam energy used for breaking bonds or cross linking them range
from 10 to 20kV.
321. What is the value of pulse time used in EBM?

a) 0.004 to 0.064 µs
b) 0.04 to 0.64 µs
c) 0.4 to 640 µs
61

d) 4 to 64000 µs
Answer: d
Explanation: Value of the pulse time of beam ranges from 4 to 64000 µs.
322. What is the value of frequency used in EBM?

a) 0.001 – 0.016 Hz
b) 0.01 – 16 Hz
c) 0.1 – 16000 Hz
d) 10 – 1600 kHz
M
Answer: c
Explanation: The frequency of the pulse range between 0.1 and 16000 Hz in Electron beam
machining.
O
323. What is the tolerance value obtained in EBM?
C
a) ± 10 %
b) ± 20 %
T.
c) ± 30 %
d) ± 40 %
O
Answer: a SP
Explanation: The tolerances obtained in Electron beam machining is about ± 10 % of the
depth of cut.
324. Which of the following are the advantages of EBM process?

G
a) Drilling rates
b) No distortion
LO
c) High accuracy
Answer: d
.B
Explanation: The main advantages of Electron beam machining are high drilling rates, no
mechanical distortion, high accuracy and repeatability.
17
325. There is no limitation imposed on which of the following factors in EBM?

a) Material ductility
b) Surface hardness
-R
c) Surface reflectivity
SE
Answer: d
Explanation: In Electron beam machining, no limitation is imposed by work piece hardness,
ductility, and surface reflectivity.
C
326. How much is the capital equipment cost of equipment used in EBM?
a) Very low cost
b) Low cost
c) Moderate cost
d) High cost
Answer: d
Explanation: The capital equipment cost of the Electron beam machining is high compared
to other machining processes.
62

327. How are the production times for a material in electron beam machining?
a) Very small
b) Small
c) Moderate
d) Long
Answer: d
Explanation: In Electron beam machining, long production times are required due to the
generation of vacuum in the chamber for machining purpose.
328. Which type of thin cast layer is produced when we use EBM?
M
a) Thin layer
b) Thick layer
c) No layer
O
C
Answer: a
Explanation: Thin recast layer is produced in Electron beam machining which an added
T.
disadvantage to the machining process
O
------------------------------------------------------------------------------------------------------------------
SP
G
LO
.B
17
-R
SE
C
63

R2017
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-
M
Applications. Principles of ECM- equipments-Surface Roughness and MRR Electrical circuit-
Process Parameters- ECG and ECH - Applications]
O
Chemical machining(CHM) / Chemical Milling – Introduction
C
1. In advanced machining processes, what is the full form of CHM?
a) Chemical machining
T.
b) Chemical manufacturing
c) Chemical milling
O
Answer: c
SP
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
G
milling process?
a) Material Vaporization
LO
b) Chemical dissolution
c) Mechanical erosion
d) Mechanical abrasion
.B
Answer: b
Explanation: Chemical dissolution takes place in Chemical milling for the removing the
material.
17
3. Which of the following solutions cannot be used as chemical reactive solution in CHM?
a) Acidic solution
-R
b) Alkaline solution
c) Neutral solution
SE
Answer: c
Explanation: Both acidic or alkane solutions are used for chemical dissolution in Chemical
milling.
C
4. By using Chemical machining, which of the following can be produced?

a) Pockets
b) Contours
c) Slots
Answer: d
Explanation: By the use of CHM, pockets, contours, slots and materials having high strength
to weight ratio can be machined.

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
M
reaction are known as _________
a) Maskants
b) Protective coverings
O
c) Protective varnishing
C
Answer: a
T.
Explanation: The protective coatings on work pieces are known as Maskants.
O
7. Type of mask depends on which of the factor/s, given below?
a) Size of work piece SP
b) Number of parts
c) Desired resolution
G
Answer: d
Explanation: All the factors mentioned above, are required to select the type of mask.
LO
8. During Chemical milling, depth of etch is controlled by which factor of immersion?

a) Time
b) Mask method
.B
c) Mask area
17
Answer: a
Explanation: As the immersion time increases, depth of the etching increases.
-R
9. What is the range of reagent temperatures used for chemical dissolution in CHM?
a) 12ᵒC to 35ᵒC
b) 37ᵒC to 85ᵒC
SE
c) 90ᵒC to 101ᵒC
d) 121ᵒC to 142ᵒC
C
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

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
M
etching rate in CHM.
12. Of the following, which ratio defines the etch factor?
O
a) Etching depth to undercut
b) Undercut to etching depth
C
c) Undercut to mask area
d) Mask area to undercut
T.
Answer: b
O
Explanation: Etch factor is defined as the ratio of undercut to etching depth.
SP
13. CHM cannot eliminate which of the following defects?
a) Irregularities and dents
b) Surface scratches
c) Waviness
G
LO
Answer: d
Explanation: CHM is not a finishing process as that of MAF, there are some sort of defects in
Chemical milling
.B
Tooling for CHM

14. Which of the following are the tools required for Chemical milling?
17
a) Maskants
b) Etchants
c) Scribing plates
-R
Answer: d
SE
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.
C
“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

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
M
Answer: d
O
Explanation: All the properties mentioned above, should be possessed by the maskants.
C
18. Which of the following can be used to apply the maskants on work piece in Chemical
milling?
T.
a) Dipping or spraying
b) Rolling or electro coating
O
c) Adhesive tapes
d) All of the mentioned SP
Answer: d
Explanation: Maskants can be applied to work piece, by the above mentioned means.
G
19. State whether the following statement is true or false regarding maskants.
“After etching, maskants should be removed easily and inexpensively.”
LO
a) True
b) False
Answer: a
.B
Explanation: After etching is done, maskants should be removed easily by inexpensive

means.
17
20. In maskant application, photo-resist masks ensure which of the following advantages?
a) High accuracy
b) Ease of repetition
-R
c) Ease of modification
SE
Answer: d
Explanation: We will have the advantages which are mentioned above, if we use photo resist
masking.
C
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.

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.
M
23. Which of the tolerance values are obtained, when we use photo resist method for
maskant application?
a) ± 0.013 mm
O
b) ± 0.045 mm
c) ± 0.077 mm
C
d) ± 0.179 mm
T.
Answer: a
Explanation: Tolerance value of ± 0.013 mm, will be obtained, when we use photo resist
O
method.
SP
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
G
LO
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.
.B
“Etchants are used for controlling H2 absorption in case of Ti alloys.”

a) True
17
b) False
Answer: a
Explanation: Etchants control the H2 absorption in Ti alloys.
-R
26. Scribing plates are used to define, which of the following parameters in Chemical
milling?
SE
a) Areas to be exposed
b) Volumes to be exposed
c) Areas not to be exposed
C
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

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
M
Answer: d
Explanation: The accessories mentioned above are included in the tooling of Chemical
milling.
O
CHM – Process Parameters and Material removal
C
29. Which of the following come under process parameters of Chemical milling?
T.
a) Reagent type
b) Concentration
c) Operating temperature
O
Answer: d
Explanation: All the parameters mentioned above, are different process parameters required
for Chemical milling.
G
30. State whether the following statement is true or false about Chemical milling.
“Maskants, applied on work pieces, are not responsible for CHM process.”
LO
a) True
b) False
.B
Answer: b
Explanation: Maskants are also responsible for process to take place in Chemical milling.
17
31. To machine high quality parts using CHM, which of the following need not be
necessary?
a) Heat treatment of work piece
-R
b) Grain size of work piece

c) Frequency of vibrations
d) Range of work pieces
SE
Answer: c
Explanation: To machine high qualities products vibrational frequency is not necessary in
CHM.
C
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.

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.
M
34. Which of the following, are the general materials used for maskant application?
a) Neoprene
b) Poly vinyl chloride
O
c) Polyethylene
C
Answer: d
T.
Explanation: All the materials mentioned above, can be used as maskant materials.
O
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.”
SP
a) True
b) False
G
Answer: b
Explanation: Material removal rate also depends on uniformity of the solution temperature.
LO
36. On which of the following factors, MRR will not be depend on?
a) Chemical uniformity
b) Metallurgical uniformity
.B
c) Frequency uniformity
d) Temperature uniformity
17
Answer: c
Explanation: Chemical milling is independent of frequency distribution.
-R
37. Castings having a larger grain size, will show how much surface roughness value?
a) Very low
b) Low
SE
c) Medium
d) High
C
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

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
M
Explanation: In Chemical milling, softer materials need low etching rates.
40. For harder materials, which of the following etching rates are obtained?
O
a) Very low
b) Low
C
c) Medium
d) High
T.
Answer: d
O
Explanation: In Chemical milling, harder materials need higher etching rates.
SP
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
G
Answer: a
LO
Explanation: High etching rates result in low surface roughness values
CHM – Accuracy and Finish

.B
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
17
c) Fine grain size and heterogeneous metallurgy

d) Coarse grain size and homogenous metallurgy
-R
Answer: a
Explanation: In CHM, for best surface quality, fine grain size and homogenous metallurgical
work piece must be required.
SE
43. Which of the following are the factors, on which, surface finish depends?
a) Grain size
b) Heat treatment
C
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.”

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
M
Answer: b
Explanation: Using CHM, surface imperfections cannot be eliminated.
O
46. Which type of etching rate, mentioned below, produces low surface roughness?
C
a) Very low
b) Low
T.
c) Medium
d) High
O
Answer: d SP
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
G
machining rates.
a) Very smaller
LO
b) Smaller
c) Medium
d) Larger
.B
Answer: d
Explanation: In Chemical milling, tolerance increases when machining depth increases.
17
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
-R
c) 0.050 mm/min
d) 0.075 mm/min
SE
Answer: c
Explanation: While we use Chemical milling etch rates of around 0.025 mm/min are
achieved.
C
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.

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.
M
51. What is the value of surface roughness, which is generally obtained using Chemical
milling?
a) 0.01 – 0.08 µm
O
b) 0.1 – 0.8 µm
c) 1 – 8 µm
C
d) 10 – 80 µm
T.
Answer: b
Explanation: Surface roughness obtained when general conditions are applied, is between
0.1 – 0.8 µm.
O
SP
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
G
d) 0.075 – 0.1 µm
LO
Answer: b
Explanation: Surface roughness obtained when special conditions are applied, is between
0.025 – 0.05 µm.
.B
53. Which of the following can be easily removed using Chemical milling process?
a) TiO2 layer
17
b) Decarburized layer
c) Recast structure
-R
Answer: d
Explanation: All the layers mentioned above, can be removed using Chemical milling.
SE
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.”
C
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
10

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
M
c) Complex
O
Answer: c
Explanation: Weight reduction can be possible using Chemical milling, on complex contours,
C
compared to conventional machining.
T.
57. Simultaneous material removal using Chemical milling, results in which of the following?
a) Improves productivity
O
b) Reduces wrapping
c) Minimizing part distortion SP
Answer: d
Explanation: All the factor mentioned above occur, when we use Chemical milling for
G
material removal.
LO
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
.B
Answer: a
17
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?
-R
a) Discontinuous
b) Continuous
c) Periodic
SE
Answer: b
C
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.
11

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
M
b) Finishing operations
c) Drilling operations
O
Answer: d
C
Explanation: Absence of burrs and good surface quality eliminates finishing operations in
CHM.
T.
63. State whether the following statement is true or false about advantages.
“Extensive web areas and decorative finishes are not possible using CHM.”
O
a) True SP
b) False
Answer: b
Explanation: Decorative finishes are obtained when we use CHM.
G
64. What are the values of scrap rates obtained in Chemical milling?
LO
a) 1%
b) 3%
c) 5%
d) 7%
.B
Answer: b
17
Explanation: Low scrapes rates around 3% are obtained when we use the Chemical milling
process
CHM-Limitations
-R
65. Which of the following are the limitations of Chemical milling process?
a) Disposal of chemicals
SE
b) Limited scribing accuracy

c) Surface imperfections
C
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
12

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
M
Explanation: All the factors mentioned above, are main disadvantages for different
processes in CHM.
O
68. Which type of metallurgical surfaces are needed in Chemical milling process?
a) Homogenous
C
b) Heterogeneous
c) Mixture
T.
O
Answer: a
Explanation: Metallurgic homogenous surfaces are needed for chemical milling to take
SP
place.
69. Porous castings yield, which type of surfaces in Chemical milling process?
a) Uniform surfaces
G
b) Even surfaces
c) Uneven surfaces
LO
Answer: c
Explanation: As there are porous castings, there would be pores on the surface which lead
.B
to uneven surfaces.
17
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
-R
Answer: b
Explanation: Welded areas etch at a different rate, when compared to that of base material.
SE
71. The absence of residual stresses on the chemically machined surfaces can produce
__________ strength.
C
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
13

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
M
Answer: d
Explanation: Hydrogen pick up, intergranular attack are some other limitations in Chemical
O
milling process.
C
74. Which of the following is not a limitation of Chemical milling process?
a) Steep tapers not practical
T.
b) Low scrap rates
c) Less scribing accuracy
O
d) Deep narrow cuts
Answer: b
SP
Explanation: Low scrap rates are possible in Chemical milling, which is an advantage to the
process
G
CHM-Applications
LO
76. Which of the following metals can be machined using the Chemical milling process?
a) Copper
b) Zinc
c) Steel
.B
Answer: d
17
Explanation: Zinc, copper, lead, and nickel are some of the metals that can be chemically
machined.
-R
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
SE
c) 2.54 – 12.27 mm
d) 13.3 – 104.56 mm
Answer: c
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
14

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
M
Answer: a
Explanation: Shallow cuts in large thin sheets helps in reducing the weight, especially in
aerospace industries.
O
80. How many designs can be machined from the same sheet in Chemical milling?
C
a) Only one
b) Two
T.
c) Three
d) Multiple
O
Answer: d SP
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
G
of the following processes?
a) Forging
LO
b) Casting
c) Sheet metal forming
.B
Answer: d
Explanation: CHM is used for applications mentioned above of the parts, which are formed
17
by casting, forging and sheet metal forming processes.
82. Removal of sharp burrs come under which application of Chemical milling process?
a) Deep cuts
-R
b) Multiple part machining

c) Improving surface characteristics
SE
Answer: c
Explanation: Removal of sharp burrs improve the surface characteristics of parts machined
C
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.
15

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.
M
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
O
b) False
C
Answer: a
Explanation: Removal of thin surfaces is done to detect the hidden defects in surfaces using
T.
CHM
O
SP
Electro Chemical Machining (ECM)
Introduction and Principle of electrolysis
86. In advanced machining processes, what is the full form of ECM?
G
a) Electrochemical manufacturing
b) Electrochemical milling
LO
c) Electrochemical machining
d) Electrochemical masking
.B
Answer: b
Explanation: In advanced machining processes, full form of ECM is Electrochemical
machining.
17
87. In the following scientists, who was the one to introduce first patent on ECM?
a) Balamuth
b) Steve O Flawer
-R
c) Gusseff
d) McGeough
SE
Answer: c
Explanation: Gusseff was the one, who introduced the first patent on ECM in 1929.
C
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?
b) Electrochemical dissolution
16

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
M
Answer: c
Explanation: When there is an electron flow there is current flow in the opposite direction.
O
For electrolysis to take place there should be flow of current between electrodes.
C
90. The system which consists of electrolytic solution and electrodes can be referred to as
____________
T.
a) Electrolytic cell
b) Electrode system
O
c) Electrolytic system
d) Electrode cell SP
Answer: a
Explanation: The system of electrodes and electrolytic solution is referred as electrolytic cell.
G
91. The chemical reactions occurring at electrodes are called with, which of the following
names?
LO
a) Anodic reactions
b) Cathode reactions
.B
Answer: c
17
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?
-R
a) Amount of electricity
b) Frequency of vibrations
c) Amplitude of oscillations
SE
Answer: a
C
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
17

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.
M
95. What are the values of voltages used in ECM?
a) 1 to 8 V
O
b) 10 to 30 V
c) 40 to 80 V
C
d) 90 to 110 V
T.
Answer: b
Explanation: Low voltages, ranging between 10 to 30 V are used in Electrochemical
machining.
O
96. How does the current pass between the two electrodes in ECM?
SP
a) Electrolytic solution
b) Direct contact of electrodes
G
LO
Answer: a
Explanation: Current passes through the solution of electrolyte, which fills the gap between
the electrodes.
.B
97. What is the value of velocity with which, electrolyte flows in the inter electrode gap?
a) >1 m/s
b) >3 m/s
17
c) >5 m/s
d) >10 m/s
-R
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.
SE
98. Of the following, electrolyte removes which of the dissolution products?

a) Metal hydroxides
b) Heat
C
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
18

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
M
Answer: d
Explanation: All the reactions mentioned above, take place at different electrodes in ECM.
O
101. Which of the following reaction takes place at anode?
C
T.
c) Generation of hydroxyl ions
O
Answer: b SP
Explanation: At anode, dissolution of Fe takes place in the process of ECM.
102. Which of the following reactions take place at cathode?

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

17
a) Anode
b) Cathode
c) Anode & Cathode
-R
Answer: b
Explanation: Positively charge particles are directed towards the cathode, which is
SE
negatively charged.
104. Negatively charged particles (anions) move towards which electrode?

C
a) Anode
b) Cathode
c) Anode & Cathode
Answer: a
Explanation: Negatively charged particles are directed towards the anode, which is positively
charged.
19

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.
M
106. Feed control system is responsible for which action in ECM?
a) Giving feed to tool
b) Electrolyte supply
O
c) Power supply
C
T.
Answer: a
Explanation: Feed control system is used for feeding the tool at constant rate during
equilibrium machining.
O
107. In ECM equipment, what is the role of electrolyte supply system?
SP
c) Power supply
G
Answer: b
LO
Explanation: As the name itself indicates, electrolyte supply system is used to supply the
electrolyte required for anodic dissolution.
.B
108. What is the role of power supply unit in ECM equipment?

17
c) Power supply
-R
Answer: c
Explanation: In ECM, power supply unit is used to supply the machine current at constant dc
voltage.
SE
109. For large size machining, which type of facilities are used in ECM?
a) Semi-automated facilities
b) Automated facilities
C
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
M
Answer: b
Explanation: For high strength and rigidity, non-metallic coatings are recommended for
O
metals.
C
111. What is the value of voltage that the power supply unit supplies for ECM?
a) 0.01 to 1 V
T.
b) 2 to 30 V
c) 50 to 80 V
O
d) 100 to 160 V
Answer: b
SP
Explanation: Voltage supply required for ECM ranges between 2 to 30 V.
112. Between which of the following values, does the current range?
G
a) 0.002 to 0.01 A
b) 0.01 to 10 A
LO
c) 50 to 10000 A
d) 105 to 106 A
Answer: c
.B
Explanation: In Electrochemical machining, current value ranges between 50 to 10000 A.

17
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
-R
d) 1200 to 2800 A/cm2
Answer: b
SE
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?

C
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
M
Answer: d
Explanation: For determining a tool geometry we must specify some factors such as the
O
required shape of the surface, tool feed rate, gap voltage, electrochemical machinability of
the work material, electrolyte conductivity, and both electrodes’ polarization voltages.
C
117. Which of the following are the simplest methods for applying the insulation on tools?
T.
a) Spraying
b) Dipping
O
d) None of the mentioned SP
Answer: c
Explanation: In ECM, dipping or spraying are the simplest methods for insulating the tools.
G
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
LO
and less accurately.”

a) True
b) False
.B
Answer: b
Explanation: Using CIM, cathodes are produced at low costs and more accurately
17
119. What are the main functions of electrolyte in Electrochemical machining?

a) Conduct machining current
-R
b) Removal of debris
c) Maintaining constant temperature
SE
Answer: d
Explanation: Main functions of electrolyte are conducting machine current, removing the
debris, carrying away the heat, maintaining constant temperature.
C
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
M
c) High
O
Answer: c
Explanation: High electrical conductivity is needed for electrolytic solution in ECM.
C
123. What are the other features of electrolytic solution in ECM?
T.
a) Non toxic
b) Less erosive
O
c) Less viscous
Answer: d
Explanation: Electrolytic solution should be nontoxic, less viscous and less erosive.
G
124. How much should be the electrolytic solution?
a) Highly expensive
LO
b) Inexpensive
.B
Answer: b
Explanation: Electrolyte must be inexpensive and available at ease.
17
125. Which are the most common electrolytes used in Electrochemical machining?
a) Sodium chloride
b) Sodium nitride
-R
c) Sodium hydroxide
SE
Answer: d
Explanation: Electrolytes such as sodium chloride, sodium nitride, sodium hydroxide are
some of the electrolytes used in ECM.
C
126. Selection of electrolyte does not depend on which of the following factors?
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
M
b) 10 to 80 kPa
c) 100 to 200 kPa
d) 300 to 400 kPa
O
Answer: c
C
Explanation: Value of pressure of electrolytic solution must range between 100 to 200 kPa.
T.
129. What must be the value of velocity of the electrolytic solution?
a) 10 to 15 m/s
O
b) 25 to 50 m/s
c) 60 to 100 m/s SP
d) 120 to 200 m/s
Answer: b
Explanation: Typical velocity of the electrolytic solution must range between 25 to 50 m/sec.
G
130. Local metal removal rates are high at which gap locations mentioned below?
LO
a) Small gap
b) Medium gap
c) Large gap
.B
Answer: a
17
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?
-R
a) High
b) Medium
c) Low
SE
d) Very low
Answer: a
C
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
M
134. What is the approximate value of faraday’s constant?
a) 65,200 C
O
b) 53,800 C
c) 96,500 C
C
d) 85,600 C
T.
Answer: c
Explanation: 1 faraday equals to approximately 96500 C.
O
135. In the following ratios of metal dissolved amounts, which one represent the current
efficiency?
a) Observed to theoretical
SP
b) Theoretical to observed
G
LO
Answer: a
Explanation: In electrochemical machining, current efficiency is the ratio of observed amount
of metal dissolved to the theoretical amount of metal dissolved.
.B
136. Apparent current efficiency is due to which of the following factors?

a) Choice of wrong valence
b) Passivation of anodic surface
17
c) Gas evolution at anode

-R
Answer: d
Explanation: Current efficiency may be apparent because of choice of wrong valence,
passivation of anodic surface or gas evolution at anodic surface.
SE
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
C
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
M
Answer: c
Explanation: At constant feed rate, work piece becomes stationary and thus the gap
O
thickness becomes constant.
C
140. At constant gap thickness material removal becomes equal to feed rate. What is this
gap called?
T.
a) Equal gap
b) Equilibrium gap
O
c) Unique gap
d) Narrow gap SP
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’.
G
141. If the gap thickness is greater than equilibrium thickness what will be MRR?
LO
a) MRR is less than feed rate

b) MRR is greater than feed rate
c) MRR is equal to feed rate
.B
Answer: a
17
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?
-R
a) Wider
b) Narrow
c) Small
SE
Answer: a
C
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.
M
145. Better surface finish and higher accuracy depend on which of the factors below?
O
a) Chemical composition of the electrolyte
b) Current density
C
T.
Answer: c
Explanation: Proper chemical composition of electrolyte and proper current density are
O
responsible for better surface finish and accuracy.
SP
146. For alloys, which type of electrolyte is used in ECM?
a) Single component
b) Double component
G
c) Multi component
d) Triple component
LO
Answer: c
Explanation: Depending up on the elements in an alloy multi component electrolytes are
used.
.B
147. Nickel can be machined with 100% current efficiency, when current density value is
______________
a) 10 A/cm2
17
b) 25 A/cm2
c) 45 A/cm2
d) 80 A/cm2
-R
Answer: b
Explanation: Nickel is a metal suggested by Khayry, which can be machined at 100% current
SE
efficiency, if current density is 25 A/cm2.
148. When the electrolyte flow is low, what happens to the current efficiency?
a) Increases
C
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.”
M
a) True
b) False
O
Answer: a
Explanation: Machinability is increased, when electrolyte is heated, as heating increases the
C
specific conductivity of the electrolyte.
T.
151. In practice, what must be the temperature of electrolyte used in ECM?
a) 10 – 20oC
b) 20 – 40oC
O
c) 60 – 80oC
d) 80 – 100oC
SP
Answer: c
Explanation: Temperature of electrolyte used in ECM must not exceed 60 – 70oC.
G
152. What is the value of moderate level of pH of electrolyte used?

LO
a) 1 – 2
b) 2 – 4
c) 4 – 10
.B
Answer: c
17
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
-R
c) 30 V
d) 40 V
SE
Answer: b
Explanation: The electrolytes in ECM employ a working voltage up to 20 V.
C
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
M
b) 0.30 to 1.90 µm
c) 1.93 to 2.64 µm
d) 2.73 to 4.26 µm
O
Answer: b
C
Explanation: Surface roughness varies between 0.30 to 1.9 µm for frontal gap area.
T.
156. Between which values does the side gap’s surface roughness vary?
a) >1 µm
O
b) >3 µm
c) >5 µm SP
d) >7 µm
Answer: c
Explanation: Surface roughness value is 5 µm or more for side gap areas.
G
157. In Electrochemical machining, larger grain size causes which type of finish?
LO
a) Smoother
b) Rougher
c) Finer
.B
Answer: b
17
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?
-R
a) Very small
b) Small
c) Medium
SE
d) High
Answer: b
Explanation: A small gap width represents a high level of accuracy. Very small gap width
C
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
M
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?
O
a) High feed rate
b) High conductivity
C
c) High feed rate & High conductivity
T.
Answer: c
O
Explanation: For a higher degree of accuracy, there must be high feed rates and highly
conductive electrolytes. SP
162. Tool insulation that __________ the side machining action is needed in the process of
ECM.
a) Limits
G
b) Enhances
c) Maintains
LO
Answer: a
Explanation: Tool insulation is needed, which limits the machining of other sides of work
.B
piece.
17
163. If the current density is high as required, what type of machining occurs?
a) Pitting
b) Polishing
c) Etching
-R
Answer: b
SE
Explanation: When the current density is relatively high as required, then polishing occurs.
164. What happens when the current density is low in ECM?

C
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
M
b) Passive layer on cathode
c) Passive layer on machined parts & cathode
O
Answer: a
C
Explanation: Passivation is done on the electrolytes in order to form a passive film on
machined parts.
T.
167. If there is an increase in the electrolyte flow, what happens to the rate of film
O
formation?
a) Increases SP
b) Decreases
c) Remains same
G
Answer: b
Explanation: An increase in electrolytic solution flow decreases the anodic product formation,
LO
which reduces the rate of film formation.
168. What are the typical dimensional tolerances for frontal gaps in ECM?
a) ± 0.01 mm
.B
b) ± 0.025 mm
c) ± 0.13 mm
17
d) ± 0.25 mm
Answer: c
Explanation: The dimensional tolerances obtained for frontal gaps are ± 0.130 mm.
-R
169. What are the tolerance values for the side gap in ECM?
a) ± 0.01 mm
SE
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
C
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
M
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?
O
a) 0.3 mm
b) 0.5 mm
C
c) 0.7 mm
d) 0.9 mm
T.
Answer: b
O
Explanation: An overcut of 0.5 mm is obtained when machined using ECM
ECM-Process Control
SP
173. If there is a change in the selected machining conditions, it will have impact on which
of the following?
G
a) Process accuracy
b) Surface finish
LO
c) Process accuracy & Surface finish

Answer: c
.B
Explanation: Selected machining conditions should remain unchanged, because, it will have
a direct impact on accuracy and surface finish.
17
174. Surface roughness depends on current density, which is affected by which of the
following?
a) Tool feed rate
-R
b) Gap voltage
c) Work piece material
SE
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.
C
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
M
such as gas generation, passivation, heating and other electrode reactions.
177. For large components, actual machining time constitutes to how much percentage of
O
the total machining time?
a) Very low
C
b) Low
c) Medium
T.
d) High
O
Answer: d
Explanation: Actual machining time of large components constitutes to a high percentage of
SP
total machining time.
178. What happens to the product cycle time, if the machining performance is improved?
a) Increases
G
b) Decreases
c) Remains same
LO
Answer: b
Explanation: As the machining performance is improved, the time take for a product to
.B
complete its production cycle, decreases.

17
179. The cost of additional control hardware remain a _________ fraction of total machining
cost.
a) Small
b) Large
-R
c) Equal
SE
Answer: a
Explanation: Cost of additional control hardware is very less, which constitutes to a small
fraction in total machining cost.
C
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.
M
182. Which type of damage is caused by deterioration which is caused by spark?
a) Reparable
b) Irreparable
O
C
Answer: b
T.
Explanation: Deterioration by sparking may cause irreparable damage to the work pieces
O
ECM-Applications and Micro-ECM
183. Which of the following use ECM for different applications?
a) Gas turbines
SP
b) Jet engines
c) Bio medical implants
G
LO
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?
.B
a) Die sinking
b) Profiling and contouring
c) Drilling and trepanning
17
Answer: d
-R
Explanation: ECM can be used for die sinking, trepanning, drilling, contouring, grinding and
profiling.
SE
185. Which of the following material cannot be machined using ECM?

a) High strength alloys
b) Hardened steels
c) Nonconductive materials
C
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
M
Answer: b
O
Explanation: ECM is usually characterized as low accuracy machining because of its wider
machining gap.
C
188. In micro ECM, which of the following is used as micro tool?
T.
a) Electrolyte jet
b) Electrodes
O
c) Power supply
Answer: a
Explanation: Electrolyte jet in micro ECM acts as the micro tool for machining.
G
189. Micro ECM is used to machine which type of parts?
a) Large parts
LO
b) Micro parts
c) Normal sized parts
.B
Answer: b
Explanation: Micro ECM is used to machine micro parts which can be from micro scale to
17
mesoscale in size.
190. Which of the following produces small indents and cavities using micro ECM?
a) Moving the work piece
-R
b) Switching the pulse current

c) Moving the work piece & Switching the pulse current
SE
Answer: c
Explanation: Indentation and cavitation can be done using micro ECM by moving the work
C
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
M
Explanation: The tool wear is absent in the tool used in ECM, since tool has no contact with
the work piece.
O
193. Compared to other processes, machining is done at __________ voltages for high
rates of material removal.
C
a) Low
b) Medium
T.
c) High
d) very low
O
Answer: c SP
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?
G
a) 0.01 mm
b) 0.05 mm
LO
c) 0.07 mm
d) 0.12 mm
Answer: b
.B
Explanation: Due to less electrode gap very small dimensions up to 0.05 mm can be
controlled.
17
195. Complicated profiles can be machined in how many operations in Electrochemical

machining?
a) Single
-R
b) Double
c) Triple
d) Multiple
SE
Answer: a
Explanation: One of the main advantage of ECM is, complicated profiles can be machined in
C
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
M
machining?
a) Low
b) Medium
O
c) High
d) Very high
C
Answer: a
T.
Explanation: In electrochemical machining, labour requirements are low compared to
conventional or traditional machining practices.
O
199. How much amount of energy is consumed in Electro chemical machining?
SP
a) Very small
b) Small
c) Medium
d) Large
G
Answer: d
LO
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
.B
methods?
a) Slower
17
b) Faster
c) Same
-R
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.
SE
“In ECM, cleaning and oiling of work piece need not be done after machining.”
a) True
b) False
C
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.
M
203. Electro chemical machining process cannot produce which of the following mentioned
below?
O
a) Drilled holes
b) Deburred edges
C
c) Sharp edges
T.
Answer: c
O
Explanation: Electro chemical machining cannot produce sharp internal or external edges.
SP
204. Pumping of electrolyte through the narrow gaps causes, which type of forces on tool
and work piece?
a) Large
b) Small
G
c) Negligible
d) No force
LO
Answer: a
Explanation: Electrolyte pumping through the narrow gaps gives rise to a large amount of
forces on tool and work pieces
.B
17
-R
SE
C
38

R2017
UNIT IV - ADVANCED NANO FINISHING PROCESSES
[Syllabus]
[ Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing,

magneto rheological finishing, magneto rheological abrasive flow finishing their working
principles, equipments, effect of process parameters, applications, advantages and
M
limitations]
O
Magnetic Abrasive Finishing – Introduction
1. In this type of machining, machining forces are controlled by which of the following
C
fields?
a) Magnetic field
T.
b) Electric field
c) Radiative field
O
Answer: a
SP
Explanation: In this machining, the magnetic field controls all the major forces of machining.
2. Which of the following type of tools, are required for magnetic field assisted polishing?
G
a) Rigid tools
b) Expensive tools
LO
c) Magnetic tools
d) Ultra precession tools
Answer: c
.B
Explanation: Magnetic field assisted polishing requires only magnetic machining elements,
for the purpose of machining.
17
3. Which of the following is not a magnetic field assisted machining process?

a) Electro-plating process
b) Magnetic abrasive finishing
-R
c) Magnetic float polishing

SE
Answer: a
Explanation: There are only two types of magnetic field assisted polishing: Magnetic
abrasive machining and Magnetic float polishing.
C
4. In the advanced machining processes, what is the full form of MAF?

a) Magnet Automated Finishing
b) Magnetic Abrasive Finishing
c) Magnet Assisted Floating
d) Magnetic Association for Floating
Answer: b
Explanation: In advanced machining processes, full form of MAF is Magnetic Abrasive
Finishing.

5. In Magnetic abrasive finishing, which of the following particles do not contribute to the
material removal?
a) Abrasive particles
b) Magnetic particles
c) Non-magnetic particles
Answer: c
Explanation: Material is removed by colloidal dispersion of the magnetic particles in abrasive
particles.
M
6. Which of the following motions are opted, in order to carry on with the Magnetic abrasive
finishing?
a) Rotary motion
O
b) Oscillatory motion
c) Vibratory motion
C
T.
Answer: d
Explanation: All the motions mentioned above, are needed for machining parts in MAF.
O
7. Magnetic Abrasive finishing is used for which of the following application/s?
a) Surface finishing SP
b) Cutting
c) Drilling
d) Boring
G
Answer: a
Explanation: Magnetic abrasive finishing is a process, which is opted for finishing of parts
LO
that are already machined on the other machines.
7. Which is the place, where Magnetic field assisted polishing was invented?
a) The United States of America
.B
b) The United Arab Emirates

c) Union of Soviet Socialist Republics
17
d) Japan
Answer: a
Explanation: Magnetic field assisted polishing was invented in the United States of America.
-R
8. Which of the following processes cannot be machined using Magnetic abrasive

finishing?
SE
a) Surface finishing
b) Surface polishing
c) Hole Drilling
C
Answer: c
Explanation: Holes drilling is one of the processes that cannot be done using Magnetic
Abrasive Finishing
MAF – Machining System

9. Which of the following components, come under machining system of Magnetic
Abrasive finishing?
a) Rotatory spindle

b) Oscillating Magnets
c) Holding chuck
Answer: d
Explanation: The components, which are mentioned above come under machining system of
Magnetic Abrasive Finishing.
10. Which of the following materials can be machined using Magnetic Abrasive finishing?
a) Alloy steels
b) Ceramic materials
M
c) Iron materials
O
Answer: d
Explanation: Magnetic abrasive finishing is a process which is used for different materials,
C
magnetic and nonmagnetic.
T.
11. State whether the following statement is true or false about Magnetic abrasive finishing.
“Vibratory motion that is axial, is introduced in the magnetic field by the oscillation of
magnetic poles.”
O
a) True SP
b) False
Answer: a
Explanation: Axially vibrating motion is required for machining in MAF.
G
12. Which of the following material/s is/are used to hold the abrasives, in MAF?
LO
a) Nonmagnetic materials
b) Ferro magnetic materials
c) Ceramic materials
.B
Answer: b
17
Explanation: Ferro magnetic materials hold the abrasives in order to remove material
through finishing.
13. What is the other name of ferromagnetic material used for holding the abrasives in
-R
MAF?
a) Magnetic abrasive conglomerate
b) Magnetic abrasive holder
SE
c) Magnetic abrasive container

d) Magnetic abrasive ampule
C
Answer: a
Explanation: Ferro magnetic material is also called as Magnetic abrasive conglomerate.
14. What are the sizes magnetic abrasive conglomerates required in the machining system
of MAF?
a) 1 – 10 microns
b) 20 – 50 microns
c) 50 – 100 microns
d) 100 – 200 microns

Answer: c
Explanation: The sizes of magnetic abrasive conglomerates range between 50 – 100
microns.
15. What are the size ranges of the abrasives used in Magnetic abrasive finishing?
a) 0.1 to 1 microns
b) 1 to 10 microns
c) 10 to 100 microns
d) 100 to 1000 microns
Answer: b
M
Explanation: The size of abrasives used for finishing range between 1 to 10 microns.
16. Which of the following are commonly used magnetic materials in finishing process?
O
a) Iron and iron oxides
b) Nickel and cobalt
C
c) Steel and stainless steel
T.
Answer: d
O
Explanation: All the materials mentioned above, are commonly used magnetic materials.
SP
17. Which of the following are commonly used abrasive materials in finishing process of
MAF?
a) Silicon Carbide
b) Aluminium Oxide
G
c) Cubic Boron Nitride
LO
Answer: d
Explanation: All the materials mentioned above, are used as abrasives in Magnetic abrasive
finishing process.
.B
18. Which of the following materials combine to form the magnetic abrasive brush in MAF?
17
a) Work piece
b) Magnetic and abrasive particles
c) Magnets
-R
Answer: d
Explanation: All the materials mentioned above, combine to form the magnetic abrasive
SE
brush.
19. In order to achieve uniform circulation of abrasives, the magnetic abrasives are
C
undergone through which of the following?

a) Stirring
b) Oscillation
c) Vibration
Answer: a
Explanation: To achieve uniform circulation of abrasives, the abrasives are undergone
thorough stirring.

20. Magnetic lines of force flows on which part of the work piece material?
a) Through the work piece
b) Over the surface
c) Above the work piece
d) Below the work piece
Answer: a
Explanation: Magnetic lines of force flow through the work piece.
MAF – Process parameters and MRR

21. What is the limit of the roller speed used in MAF?
M
a) Up to 0.5 m/s
b) Up to 1.3 m/s
O
c) Up to 2.6 m/s
d) Up to 3.3 m/s
C
Answer: b
T.
Explanation: Roller speed used can be up to 1.3 m/s.
22. What is the value of magnetic field intensity used in MAF?
O
a) 0 – 0.53 Tesla
b) 0.6 – 0.70 Tesla
c) 0.70 – 0.90 Tesla
SP
d) 0.90 – 1.1 Tesla
G
Answer: a
Explanation: Value of the magnetic field intensity used in MAF range between 0 – 0.53
LO
Tesla.
23. What is the value of magnetic pressure used in Magnetic abrasive machining?
a) 0 – 30 kPa
.B
b) 50 – 100 kPa
c) 100 – 200 kPa
d) 200 – 500 kPa
17
Answer: a
Explanation: In Magnetic abrasive finishing, value of magnetic pressure ranges between 0 –
-R
30 kPa.
24. What is the value of frequency used in Magnetic abrasive finishing process?
SE
a) 1 – 10 Hz
b) 12 – 25 Hz
c) 30 – 50 Hz
d) 60 – 100 Hz
C
Answer: b
Explanation: In MAF process, value of the frequencies used range between 12 – 25 Hz.
25. In which direction, oscillatory motion of magnets are carried out?

a) Axial to work piece
b) Perpendicular to work piece
c) Inclined to work piece

Answer: a
Explanation: Axial oscillation motion of magnets takes with respect to work piece.
26. Which of the following surface defects are removed using Magnetic abrasive finishing?
a) Scratches
b) Hard spots
c) Lay lines and tool marks
Answer: d
Explanation: All the surface defects mentioned above, can be removed using Magnetic
M
abrasive finishing.
27. What is the value of the limited depth to which form errors, tapers, looping can be
O
corrected?
a) 10 microns
C
b) 20 microns
c) 30 microns
T.
d) 40 microns
O
Answer: b
Explanation: Form errors, tapers, looping etc.., can be corrected up to a limited depth of 20
SP
microns.
28. State whether the following statement is true or false about magnetic abrasive finishing.
“Increasing the magnetic flux density raises the rate of material removal in finishing.”
G
a) True
b) False
LO
Answer: a
Explanation: In MAF, as the magnetic flux density increases, material removal rate
increases.
.B
29. Which of the following factors, does material removal rate depend on?
17
a) Magnetic flux density

b) Working clearance
-R
Answer: d
Explanation: All the factors mentioned above, are responsible for change in material removal
SE
rate.
30. Which of the following factors does not affect the magnetic abrasive conglomerates in
C
MAF?
a) Abrasive type
b) Abrasive size
d) Volume fraction
Answer: c
Explanation: In Magnetic abrasive finishing, work piece material has no effect on magnetic
abrasive conglomerates.

“Higher rates of material removal are obtained, with an increase in amplitude and
frequency.”
a) True
b) False
Answer: a
Explanation: As the amplitude and frequency increases, the rate of material removal
increases
MAF – Applications
M
32. Which of the following applications where MAF is used?
a) Finishing of inner surfaces
O
b) Polishing of balls and rollers
c) Chamfering and deburring of gears
C
T.
Answer: d
Explanation: All the applications mentioned above can be fulfilled using MAF.
O
33. Diamond abrasives used for finishing operation results in which type of surface defects?
a) Deep pits
b) Surface scratches
SP
c) Micro cracks
G
Answer: d
LO
Explanation: All the defects mentioned above occur, when we use diamond abrasives for
material removal.
34. Which of the following conditions is/are not suitable for finishing of ceramic balls?
.B
a) Controlled force
b) Large abrasive sizes
c) Small abrasive sizes
17
d) Less harder abrasives
Answer: b
-R
Explanation: For a better finish, controlled force, fine and less hard abrasives are required.
35. In MAF, ceramic balls and the bearing rollers are placed in between which components?
SE
a) Abrasives and float

b) Drive shaft and float
c) Float and magnets
d) Magnets and abrasives
C
Answer: b
Explanation: Ceramic balls are placed in between drive shaft and float.
36. Polishing in Magnetic abrasive finishing is done, by which action of material removal?
b) Mechanical erosion
c) Chemical corrosion
d) Material vaporization

Answer: a
Explanation: Abrasives are used for the polishing and finishing operations of the parts, in
Magnetic abrasive finishing.
37. State whether the following statement is true or false regarding MAF.
“As the forces exerted on the rollers are very small, polishing actions takes place very
finely.”
a) True
b) False
Answer: a
M
Explanation: Since the forces exerted are very small, polishing is very fine.
38. For obtaining a better finish using Magnetic abrasive finishing, tubes are rotated at
O
which speeds?
a) Very low
C
b) Low
c) Medium
T.
d) Very High
O
Answer: d
Explanation: To obtain a better finish in Magnetic abrasive finishing, tubes are rotated at very
SP
high speeds.
39. Which of the following is an advantage of MAF over Electrolytic finishing?

a) Disposing of electrolyte
G
b) Cost effective
c) More flexible
LO
d) More accuracy
Answer: a
Explanation: In MAF, the problem of disposing electrolyte as in case of Electrolytic finishing
.B
is not present.
17
“Mirror finishing, removed burrs with lowering the accuracy of the shape are achieved by
MAF.”
a) True
-R
b) False
Answer: b
SE
Explanation: Removed burrs without lowering the accuracy are obtained using MAF.
41. What are the other applications where Magnetic abrasive finishing can be used?
C
a) Removal of oxide layers

b) Removal of protective coatings
c) Chamfering
Answer: d
Explanation: All the processes mentioned above can be done using Magnetic abrasive
finishing

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Department of Mechanical Engineering MCQ for Regulations 2017

[Unconventional machining Process – Need – classification – merits, demerits and

2. Non-Traditional machining can also be called as ________

c) Partial contact machining

3. In which of the following industries, Non-traditional machining methods play an important

d) All of the mentioned

4. Different classifications of Non-traditional machining based on source of energy are

5. In mechanical machining, material is removed by ___________

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6. Material in thermal machining is removed by which of the following means?

9. Sources used in thermal machining are ________

d) All of the mentioned

Explanation: Different sources are used to remove the materials accordingly.

10. Vacuum is the machining medium for ________

11. In chemical machining is material removal takes by?

12. Which of the following is an example of hybrid machining?

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c) Ultrasonic assisted electrochemical machining

Water Jet Machining (WJM) – Introduction and machining system

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Explanation: Typical tube diameter values range between 6 to 14 mm.

22. What is the expected life of the nozzles used in WJM?

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WJM – Process Parameters and Material removal

c) 500 – 1500 m/s

29. State whether the following statement is true or false.

30. What is the value of material thickness of work piece in WJM?

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31. What is the value of feed rate in Water Jet Machining?

d) All of the mentioned

36. What is the tolerance limit range of thin materials in WJM?

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41. In WJM, surface treatment includes which type of processes?

WJM – Advantages and Disadvantages

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44. State whether the following statement is true or false.

d) All of the mentioned

49. Which of the following is the disadvantage of water jet machining?

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Abrasive Jet Machining (AJM) – Introduction and Machining system

which removes the material.

d) All of the mentioned

machined using Abrasive jet machining.

d) None of the mentioned

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61. State whether the following statement is true or false.

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d) None of the mentioned

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75. What is the life of Tungsten carbide material nozzle?

AJM – Applications, Advantages and limitations

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d) All of the mentioned

material by using abrasives.

85. After how much time tool has to be changed in AJM?

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Abrasive Water Jet Machining (AWJM) – Introduction