1000+ Latest MCQ’s On Advanced Machining Processes for 2023

Mechanical Processes

1. In traditional machining, which component is made of a relatively harder material?
a) Tool
b) Workpiece
c) Holding device
d) None of the mentioned
.

Answer: a
Explanation: Tool should be harder than workpiece in order to cut the workpiece according to the required geometry.

2. For machining to take place, tool should be penetrated into work piece to a certain _____________
a) Height
b) Depth
c) Length
d) Width
.

Answer: b
Explanation: Chips are removed only when certain depth is given.

3. Which motion is responsible to determine the geometry of jobs to be machined?
a) Only Motion of tool
b) Only motion of work piece
c) Relative motion between tool and work piece
d) None of the mentioned
.

Answer: c
Explanation: Relative motion between the above mentioned components are required for machining.

4. Turning is done on which type of surfaces?
a) Flat surfaces
b) Cylindrical surfaces
c) Irregular surfaces
d) Spherical surfaces
.

Answer: b
Explanation: Turning is generally used to produce cylindrical surfaces.

5. Shaping and Milling are used to generate which one of the following?
a) Cylindrical surfaces
b) Flat surfaces
c) Irregular surfaces
d) Spherical surfaces
.

Answer: b
Explanation: They are used for generation of flat surfaces.

6. Drilling is used to produce which type of geometry?
a) Slots
b) Holes
c) Profiles
d) Keyways
.

Answer: b
Explanation: Drilling is one of the processes which are used to produce holes.

7. As the temperature increases, what happens to material’s strength?
a) increases
b) decreases
c) increases and then decreases
d) remains same
.

Answer: b
Explanation: As the temperature increases, materials lose their strength.

8. As the temperature is increased, ductility is ___________
a) increased
b) decreased
c) increased and then decreased
d) remains same
.

Answer: a
Explanation: As temperature increases, ductility of material is also increases.

9. In abrasive machining __________ are used to form the tool.
a) iron particles
b) grains and grits
c) steel alloy particles
d) aluminium particles
.

Answer: b
Explanation: Grains are used as abrasive particles.

10. Abrasive machining is used when __________ is needed.
a) Cutting
b) Roughing
c) Finishing
d) Drilling
.

Answer: c
Explanation: Grains are used for finishing.

11. Non-Traditional machining is recommended when we need which of the following features?
a) Complex shapes
b) High surface quality
c) Low-rigidity structures
d) All of the mentioned
.

Answer: d
Explanation: For above requirements this machining is used.

12. Non-Traditional machining can also be called as ________
a) Contact Machining
b) Non-contact machining
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.

13. In which of the following industries, Non-traditional machining methods play an important role?
a) Automobile
b) Aerospace
c) Medical
d) All of the mentioned
.

Answer: d
Explanation: Non-traditional methods are used widely in many industries.

14. Different classifications of Non-traditional machining based on source of energy are ________
a) Mechanical
b) Thermal
c) Chemical and electro-chemical.
d) All of the mentioned
.

Answer: d
Explanation: It can be classified into the above mentioned categories.

15. In mechanical machining, material is removed by ___________
a) Erosion
b) Corrosion
c) Abrasion
d) Vaporization
.

Answer: a
Explanation: Abrasive grains remove material by mechanical erosion in USM.
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16. Material in thermal machining is removed by which of the following means?
a) Vaporization
b) Melting
c) Electro-plating
d) All of the mentioned
.

Answer: d
Explanation: In this machining, heat is the source of energy.

17. Which of the following process comes under mechanical machining?
a) USM
b) EDM
c) LBM
d) PAM
.

Answer: a
Explanation: USM removes material by mechanical erosion.

18. Surface defects that may be occurred during thermal machining are ________
a) Micro cracking
b) Heat affected zones
c) Striations
d) All of the mentioned
.

Answer: d
Explanation: During thermal machining surfaces defects occur.

19. Sources used in thermal machining are ________
a) Ions
b) Plasma
c) Electrons
d) All of the mentioned
.

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

20. Vacuum is the machining medium for ________
a) LBM
b) WJM
c) EBM
d) None of the mentioned
.

Answer: a
Explanation: Vacuum is the medium for Laser Beam Machining and Ion Beam machining.

21. In chemical machining is material removal takes by?
a) Chemical reaction
b) Erosion
c) Electron removal
d) None of the mentioned
.

Answer: a
Explanation: Chemical machining removes material by chemical reactions.

22. 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.

23. Who discovered USM?
a) Balamuth
b) Paul O Flawer
c) Turing
d) Steve John
.

Answer: a
Explanation: Balamuth was the scientist, who discovered Ultrasonic Machining.

24. What is the full form of USM in advanced machining process?
a) Ultrasound manufacturing
b) Ultrasonic machining
c) UV spectrum manufacturing
d) Ultra sonar machining
.

Answer: b
Explanation: Full form of USM in advanced machining processes, is Ultrasonic machining.

25. 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.

26. Which is softer material in USM?
a) Tool
b) Work piece
c) Tool & Work piece
d) None of the mentioned
.

Answer: a
Explanation: Tool is softer than work piece in USM.

27. Frequency of tool’s oscillation in USM ranges between ________
a) 5-10 kHz
b) 10-15 kHz
c) 18-20 kHz
d) 25-50 kHz
.

Answer: c
Explanation: Frequency used in USM is between 18 – 20 kHz.

28. Amplitude of oscillation of tool in USM ranges between ________
a) 0.1-10 μm
b) 10-40 μm
c) 50-100 μm
d) 100-1000 μm
.

Answer: b
Explanation: The optimal range used is between 10-40 μm.

29. In which year, discovery of USM took place?
a) 1910
b) 1925
c) 1943
d) 1945
.

Answer: d
Explanation: Ultrasonic Machining was discovered in 1945.

30. The machining system of USM contains which of the following components?
a) Magnetostrictor
b) Concentrator
c) Tools and slurry
d) All of the mentioned
.

Answer: d
Explanation: In machining system of USM, the above-mentioned components have to be present.

31. In Ultrasonic Machining, Magnetostrictor is energized at ultrasonic frequency.
a) True
b) False
.

Answer: a
Explanation: To oscillate, magnetostrictor must be energized to the ultrasonic frequency in USM.

32. 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.

33. In Ultrasonic Machining, magnetostrictor converts magnetic energy into which type of energy?
a) Mechanical energy
b) Electrical energy
c) Thermal energy
d) None of the mentioned
.

Answer: a
Explanation: Oscillation of magnetostrictor takes place by converting magnetic energy to mechanical energy.

34. What is the value of the amplitude obtained without mechanical amplifier?
a) 0.0001 – 0.001 µm
b) 0.001 – 0.1 µm
c) 1 – 10 µm
d) 10 – 100 µm
.

Answer: b
Explanation: Relatively very small amplitudes are obtained without amplifier.
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35. What is the value of the amplitude obtained when we use mechanical amplifier?
a) 1 – 10 µm
b) 10 – 40 µm
c) 40 – 50 µm
d) 50 – 100 µm
.

Answer: c
Explanation: Relatively larger amplitudes are obtained when amplifier is used.

36. In USM, tool tips must have low resistance and fatigue strength.
a) True
b) False
.

Answer: b
Explanation: In USM, tool tips should must have high wear resistance and fatigue strength.

37. At what rate slurry is pumped through nozzle in USM?
a) 10 L/min
b) 25 L/min
c) 50 L/min
d) 75 L/min
.

Answer: b
Explanation: Slurry is pumped through nozzle at the rate of 25 L/min, L- litres.

38. By which of the following means, material is removed in USM?
a) Mechanical abrasion
b) Microchipping
c) Cavitation
d) All of the mentioned
.

Answer: d
Explanation: In Ultrasonic Machining, material is removed by any of the above means.

39. 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.

40. In the following mechanisms, which one is dominant in material removal?
a) Hammering
b) Cavitation
c) Microchipping
d) None of the mentioned
.

Answer: a
Explanation: Hammering is dominant mechanism in material removal of USM.

41. When machining porous material, which type of mechanism is introduces?
a) Abrasion
b) Erosion
c) Corrosion
d) Vaporization
.

Answer: b
Explanation: Material removal of porous material takes place by erosion.

42. The rate of material removal depends on which of the following features?
a) Frequency
b) Static Pressure
c) Machining area
d) All of the mentioned
.

Answer: d
Explanation: Material removal rate depends on all the above mentioned factors.

43. The machinability of USM depends on brittleness criterion.
a) True
b) False
.

Answer: a
Explanation: Both machinability and MRR depends on brittleness of material.

44. Which of the following are the features of tool affecting MRR in USM?
a) Hardness
b) Wearability
c) Accuracy
d) Mounting
.

Answer: d
Explanation: Different features of tool also affect the material removal in USM.

45. 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.

46. What happens to MRR with an increase in tool amplitude?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned
.

Answer: a
Explanation: As amplitude of the tool increases, rate of material removal increases.

47. The vibration amplitude determines, which parameter of the abrasive particles?
a) Force
b) Torque
c) Velocity
d) Pressure
.

Answer: c
Explanation: Amplitude determines the velocity of abrasive particles between tool and work piece.

48. If splashing occurs, it will result in an increase of material removal rate in USM.
a) True
b) False
.

Answer: b
Explanation: Splashing occurs if amplitude is very high which in turn decreases the material removal rate.

49. Amplitude of the oscillation ranges between which of the following values?
a) 0.01 – 0.04 mm
b) 0.04 – 0.08 mm
c) 0.08 – 0.10 mm
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.

50. As the vibration frequency increases, what happens to material removal rate?
a) Decreases
b) Increases
c) Increase and then decrease
d) Decrease and then increase
.

Answer: c
Explanation: Up to a certain limit of vibration frequency, MRR increases and after that it decreases.
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51. Which of the following can be used as an abrasive carrying medium?
a) Water
b) Benzene
c) Glycerol
d) All of the mentioned
.

Answer: d
Explanation: Any of the above liquids can be used as abrasive carrying medium.

52. If there is an increase in viscosity of slurry, what happens to MRR?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned
.

Answer: b
Explanation: As viscosity is increased, material removal rate is decreased.

53. How much percent of the abrasives are recommended in general for abrasive medium?
a) 10 – 15 %
b) 15 – 20 %
c) 25 – 30 %
d) 30 – 35 %
.

Answer: d
Explanation: In practice, volumetric concentration of abrasives used range between 30 – 35 %.

54. Machining rate can be affected by the ratio of hardness of tool to that of hardness of work piece.
a) True
b) False
.

Answer: a
Explanation: In USM, Machining rate increases as the mentioned ratio decreases and vice-versa.
55. As the tool area increases, what happens to MRR?
a) Decreases
b) Increases
c) Remains same
d) None of the mentioned
.

Answer: a
Explanation: An increase in tool area distributes grains over the work piece, which reduces the machining rate.

56. When the static pressure of the feed is increases, what happens to MRR?
a) Increases
b) Decreases
c) Increase up to a limiting condition
d) Decrease up to a limiting condition
.

Answer: c
Explanation: As static feed pressure increases, MRR increases up to a limiting condition and then no further increase takes place.

57. What happens to MRR with an increase in tool amplitude?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned
.

Answer: a
Explanation: As amplitude of the tool increases, rate of material removal increases.

58. The vibration amplitude determines, which parameter of the abrasive particles?
a) Force
b) Torque
c) Velocity
d) Pressure
.

Answer: c
Explanation: Amplitude determines the velocity of abrasive particles between tool and work piece.

59. If splashing occurs, it will result in an increase of material removal rate in USM.
a) True
b) False
.

Answer: b
Explanation: Splashing occurs if amplitude is very high which in turn decreases the material removal rate.

60. Amplitude of the oscillation ranges between which of the following values?
a) 0.01 – 0.04 mm
b) 0.04 – 0.08 mm
c) 0.08 – 0.10 mm
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.

61. As the vibration frequency increases, what happens to material removal rate?
a) Decreases
b) Increases
c) Increase and then decrease
d) Decrease and then increase
.

Answer: c
Explanation: Up to a certain limit of vibration frequency, MRR increases and after that it decreases.
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61. Which of the following can be used as an abrasive carrying medium?
a) Water
b) Benzene
c) Glycerol
d) All of the mentioned
.

Answer: d
Explanation: Any of the above liquids can be used as abrasive carrying medium.

62. If there is an increase in viscosity of slurry, what happens to MRR?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned
.

Answer: b
Explanation: As viscosity is increased, material removal rate is decreased.

63. How much percent of the abrasives are recommended in general for abrasive medium?
a) 10 – 15 %
b) 15 – 20 %
c) 25 – 30 %
d) 30 – 35 %
.

Answer: d
Explanation: In practice, volumetric concentration of abrasives used range between 30 – 35 %.

64. Machining rate can be affected by the ratio of hardness of tool to that of hardness of work piece.
a) True
b) False
.

Answer: a
Explanation: In USM, Machining rate increases as the mentioned ratio decreases and vice-versa.

65. As the tool area increases, what happens to MRR?
a) Decreases
b) Increases
c) Remains same
d) None of the mentioned
.

Answer: a
Explanation: An increase in tool area distributes grains over the work piece, which reduces the machining rate.

66. When the static pressure of the feed is increases, what happens to MRR?
a) Increases
b) Decreases
c) Increase up to a limiting condition
d) Decrease up to a limiting condition
.

Answer: c
Explanation: As static feed pressure increases, MRR increases up to a limiting condition and then no further increase takes place.

67. Ultrasonic Machining can be used for which of the following processes and applications?
a) Drilling
b) Sinking and contouring
c) Polishing
d) All of the mentioned
.

Answer: d
Explanation: Ultrasonic Machining can be used for drilling holes, sinking, contouring and many more wide variety of applications.

68. 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.

69. Drilling in Ultrasonic Machining is done, by which motion of the tool?
a) Only rotation
b) Only oscillation
c) Oscillation and rotation
d) None of the mentioned
.

Answer: c
Explanation: The process, which uses USM for drilling, is known as Rotary Ultrasonic Machining (RUM).

70. In which of the following materials, Rotary Ultrasonic Machining can be used to drill holes through them?
a) Glass
b) Alumina
c) Ferrite
d) All of the mentioned
.

Answer: d
Explanation: Rotary Ultrasonic Machining can be used to drill holes in the above mentioned materials.

71. State whether the following statement is true or false.
“Rotary Ultrasonic Machining is the process in which, interrupted drilling of small-diameter holes takes place.”
a) True
b) False
.

Answer: b
Explanation: Rotary Ultrasonic Machining is the process in which, uninterrupted drilling takes place unlike traditional drilling.
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72. On which of the following features of cavity, will the penetration depth depend on?
a) Depth
b) Diameter
c) Size
d) All of the mentioned.
.

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.
73. What is the value of depth in Ultrasonic sinking, after which, material removal becomes difficult?
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.

74. 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.

75. 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
.

Answer: b
Explanation: Using Ultrasonic Polishing, very low values of surface finish can be obtained, which may be very low as 0.3 μm.

76. In Micro-Ultrasonic Machining, which of the following component vibrates?
a) Tool
b) Work piece
c) Feed pipe
d) All of the mentioned
.

Answer: b
Explanation: Unlike the normal Ultrasonic Machining, Micro-USM utilizes the work piece’s vibration and the rotation of the tool.

77. In Micro-USM, using WC tool, what is the value of diameter can be achieved?
a) 1 μm
b) 3 μm
c) 5 μm
d) 7 μm
.

Answer: c
Explanation: Diameter value up to 5 μm can be achieved, using Micro-ultrasonic machining on glass, silicon and quartz materials.

78. 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
.

Answer: b
Explanation: The full form of WJM is water jet machining in advanced machining processes.

79. What is the key element of water jet machining for material removal?
a) Tool Holder
b) Work piece
c) Water jet
d) Power source
.

Answer: c
Explanation: Water jet is the one, which is used to cut the work piece and to remove material.

80. What is the velocity of the water jet stream in water jet machining?
a) 100 m/sec
b) 300 m/sec
c) 700 m/sec
d) 900 m/sec
.

Answer: d
Explanation: Velocity of water jet stream that is used in Water jet machining is about 900 m/sec.

81. Which of the following is not a part of machining system of Water jet machining?
a) Transducer
b) Accumulator
c) Jet cutting nozzle
d) Hydraulic pump
.

Answer: a
Explanation: Transducer is not a part of Water jet machining and other components come under WJM.

82. What is the general power rating of the hydraulic pump, used in WJM?
a) 10 kW
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.
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83. Which of the following are the components of intensifier present in water jet machining system?
a) Piston
b) Plunger
c) Limit switch
d) All of the mentioned
.

Answer: d
Explanation: The above mentioned components are present in the intensifier of water jet machining.

84. 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
.

Answer: c
Explanation: Use of intensifier is to increase the inlet water pressure to 200 – 400 MPa.

85. On which property of water, will the accumulator in Water jet machining rely on?
a) Density
b) Compressibility
c) Viscosity
d) Velocity
.

Answer: b
Explanation: Accumulator relies on compressibility of water (12% at 3800bar), in order to maintain a uniform discharge pressure in WJM.

86. 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
d) 14 to 25 mm
.

87. What is the expected life of the nozzles used in WJM?
a) 10 hrs
b) 20 hrs
c) 100 hrs
d) 200 hrs
.

Answer: d
Explanation: The life that is expected from the nozzle, which is a part of machining system, is 200 hrs.

88. Which of the following does not damage the nozzle used in Water jet machining?
a) Particles of dirt
b) Mineral deposits
c) Water
d) All of the mentioned
.

Answer: c
Explanation: Only dirt particles and mineral deposits are responsible for damage of nozzle.

89. What are the uses of catcher in machining system of Water jet machining?
a) Collecting dirt
b) Collection of debris
c) Reduce noise levels
d) All of the mentioned
.

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

90. 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
Explanation: Stand-off distance is the distance between the top of work piece and nozzle outlet.

91. What is the value of diameter of the jet cutting nozzle in WJM?
a) 0.01 – 0.1 mm
b) 0.1 – 0.3 mm
c) 0.3 – 0.7 mm
d) 0.7 – 1.5 mm
.

Answer: b
Explanation: In WJM, diameter of the nozzles range between 0.10 – 0.30 mm.

92. 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
d) 6 – 14 mm
.

Answer: c
Explanation: Stand-off distance value ranges between 2.5 – 6 mm in Water jet machining.

93. What are the values of jet velocities in Water jet machining?
a) 100 – 200 m/s
b) 200 – 500 m/s
c) 500 – 1500 m/s
d) 1500 – 3000 m/s
.

Answer: c
Explanation: Velocity of the water jet stream ranges between 540 – 1480 m/s in WJM.

94. State whether the following statement is true or false.
“As the pump pressure increases, depth of cut decreases in Water jet machining.”
a) True
b) False
.

Answer: b
Explanation: As the pump pressure is increases, the depth of cut also increases in WJM.

95. 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.

96. 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.

97. In WJM, what are the properties of jet fluid that affect the MRR?
a) Velocity
b) Flow rate
c) Viscosity
d) All of the mentioned
.

Answer: d
Explanation: All the mentioned properties above, of jet fluid affect the MRR in Water jet machining.
98. Which of the following property/ies of nozzle does not affect the material removal rate in Water jet machining?
a) Material
b) Diameter
c) Outside temperature
d) Stand-off distance
.

Answer: c
Explanation: In the nozzle, outside temperature has no effect on the rate of material removal.

99. In the following materials, Water jet machining can be used on which type of material?
a) Metals
b) Plastics
c) Ceramics
d) All of the mentioned
.

Answer: d
Explanation: WJM can be used on metals, cloth, paper, plastics, food, leather, and ceramics.

100. What are the processes and applications, where Water jet machining can be used?
a) Cutting
b) Drilling
c) Deburring
d) All of the mentioned
.

Answer: d
Explanation: Water jet machining can be used for drilling, cutting, deburring, surface treatment and many more applications.

101. 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.

102. In cutting of rocks using water jet machining, which type of pressure is needed?
a) Low pressure
b) Medium pressure
c) High pressure
d) None of the mentioned
.

Answer: c
Explanation: In WJM, very high pressures and velocities are needed while cutting rocks.

103. 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
c) Low pressure and low flow rate
d) Low pressure and high flow rate
.

Answer: a
Explanation: For non-metallic materials high pressure and lower flow rates are used in deburring.
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104. Which of the following materials has some drawbacks of cutting WJM?
a) Food
b) Rocks
c) Fibre-reinforced plastics
d) None of the mentioned
.

Answer: c
Explanation: Water gets deflected due to the fibre embedded in the matrix of fibre-reinforced plastics when we use WJM.

106. 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
d) ± 0.33 mm
.

Answer: b
Explanation: In WJM, accuracy obtained in cutting of PCB’s is ± 0.13 mm.

107. In WJM, surface treatment includes which type of processes?
a) Removing deposits
b) Removing chemicals
c) Degreasing
d) All of the mentioned
.

Answer: d
Explanation: Surface treatment is done using WJM to clean the surface from many toxic chemical, deposits, residues etc

108. In how many directions, can the cutting takes place in Water jet machining?
a) Uni-directional
b) Bi-directional
c) Multi-directional
d) None of the mentioned
.

Answer: c
Explanation: Water jet machining has multi directional cutting capacity i.e.., in any direction in three dimensional space.

109. 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.

110. State whether the following statement is true or false.
“To start the cuts in Water jet machining, pre-drilled holes are not necessary.”
a) True
b) False
.

Answer: b
Explanation: In Water jet machining, we need not require any pre-drilled holes to start the cuts.

111. Which of the following is not an advantage of Water jet machining?
a) Burr produced is minimal
b) No Heat is produced
c) Relatively low hourly rates
d) Environmentally safe
.

Answer: c
Explanation: Costs per hour are relatively high in Water jet machining.

112. In Water jet machining, tool need not require sharpening once the machining is done.
a) True
b) False
.

Answer: a
Explanation: Tool does not wear in water jet machining, so it need not be sharpened.
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113. Which of the following secondary processes are eliminated in Water jet machining?
a) Grinding of surface
b) Surface treatment
c) Polishing of surface
d) All of the mentioned
.

Answer: d
Explanation: All the mentioned secondary processes above, are eliminated in Water jet machining.

114. How many parts are cut using Water jet machining, on a single blank?
a) One part
b) Two parts
c) Three parts
d) Multiple parts
.

Answer: d
Explanation: Depending up on the kerf width, multiple parts can be machined using a single blank.

115. 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.

116. 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.

117. In AJM, which of the following materials are used as abrasive grains?
a) Al2O3
b) SiC
c) Glass beads
d) All of the mentioned
.

Answer: d
Explanation: In Abrasive jet machining, any of the particles mentioned above can be used as abrasive grains.

118. In Abrasive jet machining, work piece material of removed by which of the following means?
a) Vaporization
b) Electro plating
c) Mechanical abrasion
d) Corrosion
.

Answer: c
Explanation: Abrasive particles hit the surface with high pressure and high velocities, which removes the material.

119. Which type of materials can be machined using Abrasive jet machining?
a) Glass
b) Ceramics
c) Hard materials
d) All of the mentioned
.

Answer: d
Explanation: Materials like ceramics, glass, hard and super hard materials can be machined using Abrasive jet machining.

120. In machining system of AJM, which is the medium of carrying the abrasive grains for machining?
a) Liquids
b) Gases
c) Any fluids
d) None of the mentioned
.

Answer: b
Explanation: In AJM, different types of gases are used as the medium for carrying abrasives.

121. In machining system of AJM, what is/are the gas/es used for carrying the abrasives?
a) CO2
b) Air
c) Nitrogen
d) All of the mentioned
.

Answer: d
Explanation: In AJM, gases like CO2, air or nitrogen are used to carry the abrasives.

122. 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.

123. Which of the following gas, should never be used as the carrier of abrasives?
a) Nitrogen
b) CO2
c) Oxygen
d) Air
.

Answer: c
Explanation: Oxygen should not be used as carrier because it causes a violent chemical reaction with abrasives or work piece.

124. What is the frequency of mixing chamber, consisting of gas and abrasives?
a) 10 Hz
b) 30 Hz
c) 50 Hz
d) 70 Hz
.

Answer: c
Explanation: Mixing chamber consisting of carrier gas and the abrasive grains, vibrates at a frequency of 50 Hz.

125. In Abrasive jet machining, what may be the size of the abrasive grains used?
a) 10 – 40 µm
b) 50 – 100 µm
c) 100 – 150 µm
d) 200 – 300 µm
.

Answer: a
Explanation: Abrasive grains of size, between 10 – 40 µm can be used for machining.

126. What are the processes where Abrasive jet machining can be used?
a) Cleaning
b) Cutting
c) Deburring
d) All of the mentioned
.

Answer: d
Explanation: Abrasive jet machining can be used for deburring, cutting, cleaning and for many other heavy duty applications.

127. State whether the following statement is true or false.
“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.

128. 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
d) All of the mentioned
.

Answer: d
Explanation: Relative motion in Abrasive jet machining can be controlled by the above mentioned means.

129. Masks, which are used to confine the jet stream location on work piece are made of, which type of materials?
a) Copper
b) Glass
c) Rubber
d) All of the mentioned
.

Answer: d
Explanation: Masks can be made of any of the above-mentioned materials.

130. In AJM, what is the mechanism of removal of material from the work piece?
a) Corrosion
b) Abrasion
c) Electron transfer
d) Vaporization
.

Answer: b
Explanation: In Abrasive jet machining, the removal of material takes places by mechanical abrasion, using abrasive grains.

131. In AJM, abrasive jet from the nozzle follows, which type of path for a short distance?
a) Parallel
b) Inclined
c) Perpendicular
d) None of the mentioned
.

Answer: a
Explanation: Abrasive particles follow a parallel path for short distance and then flare outward.

132. Which of the following components, influence the material removal rate in Abrasive jet machining?
a) Nozzle
b) Carrier gas
c) Abrasive grains
d) All of the mentioned
.

Answer: d
Explanation: All the components mentioned above, influence the rate of material removal, directly or indirectly.

133. 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.

134. In the following properties of abrasive grains, which of them changes rate of material removal?
a) Size
b) Strength
c) Shape
d) All of the mentioned
.

Answer: d
Explanation: The above mentioned properties of abrasive grains influence the material removal rate.
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135. As the abrasive flow rate increases, what happens to the volumetric removal rate?
a) Increases
b) Decreases
c) Increase and then decrease
d) Decrease and then increase
.

Answer: c
Explanation: In AJM, volumetric removal rate increases up to a level and then decreases.

136. What is the value of abrasive grain flow rate in Abrasive jet machining?
a) 0.1 – 2 g/min
b) 3 – 20 g/min
c) 30 – 56 g/min
d) 68 – 85 g/min
.

Answer: b
Explanation: Abrasive grain flow rate is between 3 – 20 g/min, in AJM.

137. What must be the velocity of the carrier gas that carries the abrasive particles?
a) 10 – 50 m/sec
b) 50 – 150 m/sec
c) 150 –300 m/sec
d) 300 – 500 m/sec
.

Answer: c
Explanation: Velocity of abrasive carrier gas must be between 150 – 300 m/sec.

138. What is the value of carrier gas flow rate in Abrasive jet machining?
a) 6 L/min
b) 17 L/min
c) 28 L/min
d) 39 L/min
.

Answer: c
Explanation: In Abrasive jet machining, the flow rate of abrasive carrier gas is around 28 L/min.

139. 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.

140. 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.

141. 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
.

Answer: c
Explanation: Nozzle made up of WC material has a life period which range between 10 – 15 hrs.

142. In AJM, what is the life of synthetic sapphire material nozzle?
a) 100 hrs
b) 300 hrs
c) 500 hrs
d) 700 hrs
.

Answer: b
Explanation: Nozzle made up of synthetic sapphire material has a life period which is about 300 hrs.

143. What are the tolerance limit values in Abrasive water jet machining?
a) ± 0.01 mm
b) ± 0.03 mm
c) ± 0.05 mm
d) ± 0.07 mm
.

Answer: c
Explanation: In Abrasive jet machining, tolerance limit values range between ± 0.05 mm.

144. In AJM, surface roughness value will vary between which values?
a) 0.01 – 0.10 µm
b) 0.15 – 1.5 µm
c) 2.0 – 5.0 µm
d) 7.0 – 10.0 µm
.

Answer: b
Explanation: Surface roughness value in AJM varies between 0.15 – 1.5 µm, depending on grain size.

145. Which of the following, are the processes and applications in which Abrasive jet machining can be applied?
a) Drilling
b) Cutting
c) Deburring
d) All of the mentioned
.

Answer: d
Explanation: Abrasive jet machining can be used for cutting, drilling, deburring and cleaning processes.

146. 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.

147. In Abrasive jet machining, intricate shapes and holes are machined on which type of materials?
a) Brittle
b) Thin
c) Difficult to machine
d) All of the mentioned
.

Answer: d
Explanation: Abrasive jet machining is used to machine, intricate shapes and holes in brittle, thin and difficult to machine materials.

148. 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.”
a) True
b) False
.

Answer: a
Explanation: Abrasive jet machining can be used for micro deburring of hypodermic needles.

149. What are the type of materials that can be machined using Abrasive jet machining?
a) Glass
b) Sapphire
c) Quartz
d) All of the mentioned
.

Answer: d
Explanation: In Abrasive jet machining, the above mentioned materials can be machined, which are heat sensitive and brittle.
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150. What is the amount of material utilizes when we machine parts using Abrasive jet machining?
a) Very low
b) Low
c) Medium
d) High
.

Answer: d
Explanation: In Abrasive jet machining, material utilization is very high since it removes material by using abrasives.

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

152. 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.

153. Which type of materials cannot be machined using Abrasive jet machining?
a) Soft materials
b) Hard materials
c) Difficult to machine materials
d) None of the mentioned
.

Answer: a
Explanation: Soft materials such as candy bars, thin softwood etc.., cannot be machined using AJM.

154. Which of the following materials in Abrasive jet machining can be a health hazard?
a) Abrasive grains
b) Air carrier
c) Silica dust
d) None of the mentioned
.

Answer: c
Explanation: Silica dust, that occurs after machining can be a health hazard in AJM.

155. In AJM, air filters are used to remove which of the following?
a) Moisture
b) Oil
c) Other dust particles
d) All of the mentioned
.

Answer: d
Explanation: Before machining, air has to be filtered to remove dust, moisture and oil in the machining system.

156. In advanced machining processes, what is the full form of AWJM?
a) Automated Water Jet Machining
b) Automated Water Jet Manufacturing
c) Abrasive Water Jet Machining
d) Abrasive Water Jet Manufacturing
.

Answer: c
Explanation: Full form of AWJM is Abrasive Water Jet Machining.

157. What are all the types of materials, which can be machined using AWJM?
a) Glass
b) Ceramics
c) Concrete
d) All of the mentioned
.

Answer: d
Explanation: Hard to cut materials, which are mentioned above, can be machined using Abrasive water jet machining.

158. 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.

159. 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
Explanation: Abrasive water jet machining is 10 times faster than the conventional machining.

160. What is the percentage of the abrasives and water in the mixture?
a) 20% water and 80% abrasives
b) 80% water and 20% abrasives
c) 30% water and 70% abrasives
d) 70% water and 30% abrasives
.

Answer: d
Explanation: Abrasive mixture consists of 70 percent water and 30 percent abrasives.

161. What are the materials used for abrasives in Abrasive water jet machining?
a) SiC
b) Corundum
c) Glass beads
d) All of the mentioned
.

162. In the machining system of AWJM, which one accelerates the abrasives to remove material?
a) Water only
b) Water jet stream
c) Feeder
d) None of the mentioned
.

Answer: b
Explanation: Water jet stream accelerates abrasives but not the water only, to remove material.

163. 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.

164. 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.

165. How is the material removed in Abrasive water jet machining?
a) Vaporization
b) Electron transfer
c) Corrosion
d) Erosion
.

Answer: d
Explanation: In Abrasive water jet machining, material removal takes place by the erosion of the work piece material using abrasives accelerated by jet stream.

166. Which of the following is not the feed mechanism of the abrasives in AWJM?
a) Side feed
b) Cross feed
c) Central feed
d) All of the mentioned
.

Answer: b
Explanation: Only side feed and central feed are used in Abrasive water jet machining.

167. In Abrasive water jet machining, how are the abrasives fed into the water jet stream?
a) Suspension
b) Injection
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: Abrasives are fed into the water jet stream through suspension or injection.

168. What is the use of delivery system in the machining system of AWJM?
a) To deliver colloidal solution
b) To pump water
c) To fed abrasives
d) None of the mentioned
.

Answer: b
Explanation: In Abrasive water jet machining, water delivery system is used.

169. 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.

170. 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
Explanation: In AWJM, intensifier is used to deliver high pressure water using pistons with it.
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171. In mixing chamber of AWJM, which of the following are mixed?
a) Abrasives and colloidal solution
b) Abrasives and water jet
c) Colloidal and water jet
d) None of the mentioned
.

Answer: b
Explanation: In mixing chamber, abrasives and water jet stream are mixed.

172. Of the following, which one is a type of suspension in AWJM?
a) Direct pumping
b) Indirect pumping
c) Bypass pumping
d) All of the mentioned
.

Answer: d
Explanation: There are three different types of suspension AWJ formed by indirect, direct and bypass pumping.

173. In machining system of AWJM, mixing chamber is immediately followed by which of the following component?
a) Focusing tube
b) Cutting Nozzle
c) Intensifier
d) Water delivery
.

Answer: a
Explanation: In Abrasive water jet machining, mixing chamber is immediately followed by the focusing tube.

174. Which of the following energies are absorbed using the catchers in Abrasive water jet machining?
a) Pressure energy
b) Kinetic energy of abrasives
c) Residual energy
d) All of the mentioned
.

Answer: c
Explanation: In AWJM, catchers are used to absorb the residual energy.

175. Which of the following are different types of catchers used in AWJM?
a) Water basin type
b) Submerged steel balls type
c) TiB2 type
d) All of the mentioned
.

Answer: d
Explanation: The above mentioned types are the types of catchers used in AWJM.

176. Which of the following is not a process parameter of Abrasive water jet machining?
a) Frequency of vibration
b) Orifice diameter
c) Pressure
d) Stand-off distance
.

Answer: a
Explanation: Frequency of the vibrations does not belong to the parameters of Abrasive water jet machining.

177. Which of the following come under the process parameters of the Abrasive water jet machining?
a) Abrasive size
b) Machine impact angle
c) Traverse speed
d) All of the mentioned
.

Answer: d
Explanation: All the parameters mentioned above come under Abrasive water jet machining.

178. What is the value of orifice diameter in Abrasive water jet machining?
a) 0.01 – 0.03 mm
b) 0.03 – 0.09 mm
c) 0.10 – 0.30 mm
d) 0.30 – 0.90 mm
.

Answer: c
Explanation: The value of diameter of the orifice should range between 0.10 – 0.30 mm.

179. Of the following values, between which of them pressure value will range?
a) 1000 – 1500 bar
b) 1500 – 2500 bar
c) 2500 – 4000 bar
d) 4000 – 10000 bar
.

Answer: c
Explanation: In Abrasive water jet machining, pressure value will range between 2500 – 4000 bar.

180. 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.
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181. 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
.

Answer: a
Explanation: As rate of material removal increases in AWJM, large surface roughness are produced.

182. Surface roughness depends on which of the following parameters in Abrasive water jet machining?
a) Work piece material
b) Grit size
c) Abrasive type
d) All of the mentioned
.

Answer: d
Explanation: All the parameters mentioned above, are responsible for variation in surface roughness.

183. What is the value of focusing diameter in Abrasive water jet machining?
a) 0.1 – 0.6 mm
b) 0.8 – 1.4 mm
c) 1.6 – 2.8 mm
d) 3.2 – 5.2 mm
.

Answer: b
Explanation: Diameter value of WC focusing tube in AWJM varies between 0.8 – 1.4 mm.

184. Abrasive flow value in Abrasive water jet machining will range between which of the following values?
a) 0.01 – 0.1 kg/min
b) 0.1 – 1.0 kg/min
c) 1.0 – 10 kg/min
d) 10 – 100 kg/min
.

Answer: b
Explanation: In AWJM, abrasive flow ranges between 0.1 – 1.0 kg/min.

185. 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
.

186. Impact angle in Abrasive water jet machining range between which of the following values?
a) 0° to 10°
b) 10° to 30°
c) 30° to 90°
d) 90° to 100°
.

Answer: c
Explanation: Machine impact angle in AWJM will range between 30° to 90°.

187. Of the following values, between which values traverse speed will range?
a) 0.1 to 5 m/min
b) 5 to 100 m/min
c) 100 to 500 m/min
d) 500 to 1000 m/min
.

Answer: b
Explanation: Value of traverse speed ranges between 5 to 100 m/min.

188. Depth of cut values in Abrasive water jet machining ranges between which values?
a) 0.01 to 2 mm
b) 2 to 250 mm
c) 300 to 500 mm
d) 650 to 900 mm
.

Answer: b
Explanation: The value of depth of cut in AWJM ranges between 2 to 250 mm.

189. In the existing advanced machining processes, what is the full form of IJM?
a) Ice Jet Manufacturing
b) Ink Jet Manufacturing
c) Ice Jet Machining
d) Ink Jet Machining
.

Answer: c
Explanation: Full form of IJM is Ice jet machining in advanced machining processes.

190. In Ice jet machining, the abrasive particles used for material removal are replaced by which of the following?
a) Silica particles
b) Ice particles
c) Fluids
d) Colloidal solutions
.

Answer: b
Explanation: In Ice jet machining, the abrasive particles are replaced by ice particles.

191. When compared to Abrasive water jet machining, how are the material removal rates in Ice jet machining?
a) Very low
b) Low
c) High
d) Remains same
.

Answer: b
Explanation: In Ice jet machining, material removal rates are relatively low when compared to AWJM.

192. State whether the following statement is true or false about Ice jet machining.
“Water can be reused in IJM, unlike that of AWJM and WJM.”
a) True
b) False
.

Answer: a
Explanation: Unlike that of AWJM, water can be reused in Ice jet machining.

193. Which of the following are the components of machining system of IJM?
a) High pressure pump
b) Ice particle generator
c) Ultrasonic Atomizer
d) All of the mentioned
.

Answer: d
Explanation: All the components mentioned above are present in the machining system of IJM.
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194. Which of the following component will be present just after the cooling coil?
a) High pressure pump
b) Ice particle generator
c) Cutting nozzle
d) Ultrasonic Atomizer
.

Answer: c
Explanation: Prior to nozzle water is cooled by coils that is submerged in liquid nitrogen.

195. Ice particles of size <500 µm are produced by which of the following process?
a) Stream freezing
b) Ice particles supply
c) Normal cooling
d) None of the mentioned
.

Answer: a
Explanation: Ice particles of size <500 µm are produced by using stream freezing. 196. Ice particles of size >500 µm are produced by which of the following process?
a) Stream freezing
b) Ice particles supply
c) Normal cooling
d) None of the mentioned
.

Answer: b
Explanation: Ice particles of size >500 µm are produced by ice particles supply.

197. In Ice jet machining, stand-off distance value varies between which of the following?
a) 1.0 – 2.0 mm
b) 2.0 – 3.0 mm
c) 3.0 – 5.0 mm
d) 5.0 – 10.0 mm
.

Answer: c
Explanation: Value of the stand-off distance ranges between 3.0 – 5.0 mm in IJM.

198. What is the value of diameter of nozzle that is used in Ice jet machining?
a) 0.175 mm
b) 0.425 mm
c) 0.548 mm
d) 0.654 mm
.

Answer: a
Explanation: The value of diameter of nozzle in Ice jet machining is about 0.175 mm.

199. Ultrasonic atomizer used in ice particle generator, produces water droplets at which rate?
a) 0.1 ltr/hr to 1 ltr/hr
b) 2 ltr/hr to 12 ltr/hr
c) 20 ltr/hr to 35 ltr/hr
d) 40 ltr/hr to 65 ltr/hr
.

Answer: b
Explanation: Atomizer produces droplets at the rate 2 ltr/hr to 12 ltr/hr.

200. What are the advantages of Ice jet machining over the other advanced machining processes?
a) Environmentally safe
b) Cost reduction
c) No heat affected zone
d) All of the mentioned
.

Answer: d
Explanation: Advantages of Ice Jet Machining are mentioned above when compared to other processes.

201. Which of the following is a disadvantage of ice jet machining when compared to AWJM?
a) Environmentally safe
b) Cost reduction
c) Low material removal rate
d) No heat affected zone
.

Answer: c
Explanation: When compared to AWJM, IJM has lower material removal rates.

202. Which of the following are the processes and applications by the use of IJM?
a) Ice Deburring process
b) Ice Cutting process
c) Ice Blasting process
d) All of the mentioned
.

Answer: d
Explanation: All the processes mentioned above are done by using IJM.

203. Which of the following industries use Ice jet machining for different applications?
a) Food industry
b) Medical industry
c) Space industry
d) All of the mentioned
.

Answer: d
Explanation: Different type of industries mentioned above use Ice jet machining for wide variety of applications.

204. In this type of machining, machining forces are controlled by which of the following fields?
a) Magnetic field
b) Electric field
c) Radiative field
d) None of the mentioned
.

Answer: a
Explanation: In this machining, the magnetic field controls all the major forces of machining.

205. Which of the following type of tools, are required for magnetic field assisted polishing?
a) Rigid tools
b) Expensive tools
c) Magnetic tools
d) Ultra precession tools
.

Answer: c
Explanation: Magnetic field assisted polishing requires only magnetic machining elements, for the purpose of machining.

206. Which of the following is not a magnetic field assisted machining process?
a) Electro-plating process
b) Magnetic abrasive finishing
c) Magnetic float polishing
d) All of the mentioned
.

Answer: a
Explanation: There are only two types of magnetic field assisted polishing: Magnetic abrasive machining and Magnetic float polishing.

207. 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.

208. 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
d) All of the mentioned
.

Answer: c
Explanation: Material is removed by colloidal dispersion of the magnetic particles in abrasive particles.
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209. Which of the following motions are opted, in order to carry on with the Magnetic abrasive finishing?
a) Rotary motion
b) Oscillatory motion
c) Vibratory motion
d) All of the mentioned
.

Answer: d
Explanation: All the motions mentioned above, are needed for machining parts in MAF.

210. Magnetic Abrasive finishing is used for which of the following application/s?
a) Surface finishing
b) Cutting
c) Drilling
d) Boring
.

Answer: a
Explanation: Magnetic abrasive finishing is a process, which is opted for finishing of parts that are already machined on the other machines.

211. Which is the place, where Magnetic field assisted polishing was invented?
a) The United States of America
b) The United Arab Emirates
c) Union of Soviet Socialist Republics
d) Japan
.

Answer: a
Explanation: Magnetic field assisted polishing was invented in the United States of America.

212. Which of the following processes cannot be machined using Magnetic abrasive finishing?
a) Surface finishing
b) Surface polishing
c) Hole Drilling
d) None of the mentioned
.

Answer: c
Explanation: Holes drilling is one of the processes that cannot be done using Magnetic Abrasive Finishing.

213. Which of the following components, come under the machining system of Magnetic Abrasive finishing?
a) Rotatory spindle
b) Oscillating Magnets
c) Holding chuck
d) All of the mentioned
.

Answer: d
Explanation: The components, which are mentioned above come under machining system of Magnetic Abrasive Finishing.

214. Which of the following materials can be machined using Magnetic Abrasive finishing?
a) Alloy steels
b) Ceramic materials
c) Iron materials
d) All of the mentioned
.

Answer: d
Explanation: Magnetic abrasive finishing is a process which is used for different materials, magnetic and nonmagnetic.

215. 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.”
a) True
b) False
.

Answer: a
Explanation: Axially vibrating motion is required for machining in MAF.

216. Which of the following material/s is/are used to hold the abrasives, in MAF?
a) Nonmagnetic materials
b) Ferro magnetic materials
c) Ceramic materials
d) None of the mentioned
.

Answer: b
Explanation: Ferro magnetic materials hold the abrasives in order to remove material through finishing.

217. What is the other name of ferromagnetic material used for holding the abrasives in MAF?
a) Magnetic abrasive conglomerate
b) Magnetic abrasive holder
c) Magnetic abrasive container
d) Magnetic abrasive ampule
.

Answer: a
Explanation: Ferro magnetic material is also called as Magnetic abrasive conglomerate.

218. 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.

219. 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
Explanation: The size of abrasives used for finishing range between 1 to 10 microns.

220. Which of the following are commonly used magnetic materials in finishing process?
a) Iron and iron oxides
b) Nickel and cobalt
c) Steel and stainless steel
d) All of the mentioned
.

Answer: d
Explanation: All the materials mentioned above, are commonly used magnetic materials.

221. Which of the following are commonly used abrasive materials in finishing process of MAF?
a) Silicon Carbide
b) Aluminium Oxide
c) Cubic Boron Nitride
d) All of the mentioned
.

Answer: d
Explanation: All the materials mentioned above, are used as abrasives in Magnetic abrasive finishing process.

222. Which of the following materials combine to form the magnetic abrasive brush in MAF?
a) Work piece
b) Magnetic and abrasive particles
c) Magnets
d) All of the mentioned
.

Answer: d
Explanation: All the materials mentioned above, combine to form the magnetic abrasive brush.

223. In order to achieve uniform circulation of abrasives, the magnetic abrasives are undergone through which of the following?
a) Stirring
b) Oscillation
c) Vibration
d) All of the mentioned
.

Answer: a
Explanation: To achieve uniform circulation of abrasives, the abrasives are undergone thorough stirring.

224. 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.

225. What is the limit of the roller speed used in MAF?
a) Up to 0.5 m/s
b) Up to 1.3 m/s
c) Up to 2.6 m/s
d) Up to 3.3 m/s
.

Answer: b
Explanation: Roller speed used can be up to 1.3 m/s.

226. What is the value of magnetic field intensity used in MAF?
a) 0 – 0.53 Tesla
b) 0.6 – 0.70 Tesla
c) 0.70 – 0.90 Tesla
d) 0.90 – 1.1 Tesla
.

Answer: a
Explanation: Value of the magnetic field intensity used in MAF range between 0 – 0.53 Tesla.

228. What is the value of magnetic pressure used in Magnetic abrasive machining?
a) 0 – 30 kPa
b) 50 – 100 kPa
c) 100 – 200 kPa
d) 200 – 500 kPa
.

Answer: a
Explanation: In Magnetic abrasive finishing, value of magnetic pressure ranges between 0 – 30 kPa.

229. What is the value of frequency used in Magnetic abrasive finishing process?
a) 1 – 10 Hz
b) 12 – 25 Hz
c) 30 – 50 Hz
d) 60 – 100 Hz
.

Answer: b
Explanation: In MAF process, value of the frequencies used range between 12 – 25 Hz.

230. 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
d) None of the mentioned
.

Answer: a
Explanation: Axial oscillation motion of magnets takes with respect to work piece.
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231. Which of the following surface defects are removed using Magnetic abrasive finishing?
a) Scratches
b) Hard spots
c) Lay lines and tool marks
d) All of the mentioned
.

Answer: d
Explanation: All the surface defects mentioned above, can be removed using Magnetic abrasive finishing.

232. What is the value of the limited depth to which form errors, tapers, looping can be corrected?
a) 10 microns
b) 20 microns
c) 30 microns
d) 40 microns
.

Answer: b
Explanation: Form errors, tapers, looping etc.., can be corrected up to a limited depth of 20 microns.

233. 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.”
a) True
b) False
.

Answer: a
Explanation: In MAF, as the magnetic flux density increases, material removal rate increases.

234. Which of the following factors, does material removal rate depend on?
a) Magnetic flux density
b) Working clearance
c) Work piece material
d) All of the mentioned
.

Answer: d
Explanation: All the factors mentioned above, are responsible for change in material removal rate.

235. Which of the following factors does not affect the magnetic abrasive conglomerates in MAF?
a) Abrasive type
b) Abrasive size
c) Work piece material
d) Volume fraction
.

Answer: c
Explanation: In Magnetic abrasive finishing, work piece material has no effect on magnetic abrasive conglomerates.

236. State whether the following statement is true or false about Magnetic abrasive finishing.
“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.

237. Which of the following applications where MAF is used?
a) Finishing of inner surfaces
b) Polishing of balls and rollers
c) Chamfering and deburring of gears
d) All of the mentioned
.

Answer: d
Explanation: All the applications mentioned above can be fulfilled using MAF.

238. Diamond abrasives used for finishing operation results in which type of surface defects?
a) Deep pits
b) Surface scratches
c) Micro cracks
d) All of the mentioned
.

Answer: d
Explanation: All the defects mentioned above occur, when we use diamond abrasives for material removal.

239. Which of the following conditions is/are not suitable for finishing of ceramic balls?
a) Controlled force
b) Large abrasive sizes
c) Small abrasive sizes
d) Less harder abrasives
.

Answer: b
Explanation: For a better finish, controlled force, fine and less hard abrasives are required.

240. In MAF, ceramic balls and the bearing rollers are placed in between which components?
a) Abrasives and float
b) Drive shaft and float
c) Float and magnets
d) Magnets and abrasives
.

Answer: b
Explanation: Ceramic balls are placed in between drive shaft and float.

241. Polishing in Magnetic abrasive finishing is done, by which action of material removal?
a) Mechanical abrasion
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.
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242. 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
Explanation: Since the forces exerted are very small, polishing is very fine.

243. For obtaining a better finish using Magnetic abrasive finishing, tubes are rotated at which speeds?
a) Very low
b) Low
c) Medium
d) Very High
.

Answer: d
Explanation: To obtain a better finish in Magnetic abrasive finishing, tubes are rotated at very high speeds.

244. Which of the following is an advantage of MAF over Electrolytic finishing?
a) Disposing of electrolyte
b) Cost effective
c) More flexible
d) More accuracy
.

Answer: a
Explanation: In MAF, the problem of disposing electrolyte as in case of Electrolytic finishing is not present.

245. State whether the following statement is true or false about Magnetic abrasive finishing.
“Mirror finishing, removed burrs with lowering the accuracy of the shape are achieved by MAF.”
a) True
b) False
.

Answer: b
Explanation: Removed burrs without lowering the accuracy are obtained using MAF.

246. What are the other applications where Magnetic abrasive finishing can be used?
a) Removal of oxide layers
b) Removal of protective coatings
c) Chamfering
d) All of the mentioned
.

Answer: d
Explanation: All the processes mentioned above can be done using Magnetic abrasive finishing.

MCQ’s On Chemical Processes

1. In advanced machining processes, what is the full form of CHM?
a) Chemical machining
b) Chemical manufacturing
c) Chemical milling
d) None of the mentioned
.

Answer: c
Explanation: In advanced machining processes, full form of CHM is Chemical milling.

2. Of the following, which mechanism is used for the removal of material using Chemical milling process?
a) Material Vaporization
b) Chemical dissolution
c) Mechanical erosion
d) Mechanical abrasion
.

Answer: b
Explanation: Chemical dissolution takes place in Chemical milling for the removing the material.

3. Which of the following solutions cannot be used as chemical reactive solution in CHM?
a) Acidic solution
b) Alkaline solution
c) Neutral solution
d) None of the mentioned
.

Answer: c
Explanation: Both acidic or alkane solutions are used for chemical dissolution in Chemical milling.

4. By using Chemical machining, which of the following can be produced?
a) Pockets
b) Contours
c) Slots
d) All of the mentioned
.

Answer: d
Explanation: By the use of CHM, pockets, contours, slots and materials having high strength to weight ratio can be machined.

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
d) All of the mentioned
.

Answer: d
Explanation: All the factors mentioned above, are achieved thorough pre-cleaning process.
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6. Special coatings applied on work piece materials in order to protect them from chemical reaction are known as _________
a) Maskants
b) Protective coverings
c) Protective varnishing
d) None of the mentioned
.

Answer: a
Explanation: The protective coatings on work pieces are known as Maskants.

7. Type of mask depends on which of the factor/s, given below?
a) Size of work piece
b) Number of parts
c) Desired resolution
d) All of the mentioned
.

Answer: d
Explanation: All the factors mentioned above, are required to select the type of mask.

8. During Chemical milling, depth of etch is controlled by which factor of immersion?
a) Time
b) Mask method
c) Mask area
d) None of the mentioned
.

Answer: a
Explanation: As the immersion time increases, depth of the etching increases.

9. What is the range of reagent temperatures used for chemical dissolution in CHM?
a) 12ᵒC to 35ᵒC
b) 37ᵒC to 85ᵒC
c) 90ᵒC to 101ᵒC
d) 121ᵒC to 142ᵒC
.

Answer: b
Explanation: The optimum temperature of reagent used should range between 37ᵒC to 85ᵒC.

10. In Chemical milling, excessive flow of chemical reagent results in which of the following defects?
a) Channellings
b) Grooves
c) Ridges
d) All of the mentioned
.

Answer: d
Explanation: In Chemical milling, if the reagent flows excessively, then the defects mentioned above may occur.

11. State whether the following statement about Chemical milling is true or false.
“At higher temperatures, faster etching rates occur in Chemical milling.”
a) True
b) False
.

Answer: a
Explanation: As the temperature increases, reaction rate increases which in turn increases etching rate in CHM.

12. Of the following, which ratio defines the etch factor?
a) Etching depth to undercut
b) Undercut to etching depth
c) Undercut to mask area
d) Mask area to undercut
.

Answer: b
Explanation: Etch factor is defined as the ratio of undercut to etching depth.

13. CHM cannot eliminate which of the following defects?
a) Irregularities and dents
b) Surface scratches
c) Waviness
d) All of the mentioned
.

Answer: d
Explanation: CHM is not a finishing process as that of MAF, there are some sort of defects in Chemical milling.

14. Which of the following are the tools required for Chemical milling?
a) Maskants
b) Etchants
c) Scribing plates
d) All of the mentioned
.

Answer: d
Explanation: All the components mentioned above, are required to carry out Chemical milling process.

15. State which of the following statement is true or false regarding Chemical milling.
“Maskants are generally used in CHM, to protect the work piece from the etching chemical agent.”
a) True
b) False
.

Answer: a
Explanation: In CHM, maskants are used to protect the work piece from chemical agents.

16. Which of the following are the materials used for making maskants?
a) Synthetic materials
b) Rubber materials
c) Polymeric materials
d) All of the mentioned
.

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
d) All of the mentioned
.

Answer: d
Explanation: All the properties mentioned above, should be possessed by the maskants.

18. Which of the following can be used to apply the maskants on work piece in Chemical milling?
a) Dipping or spraying
b) Rolling or electro coating
c) Adhesive tapes
d) All of the mentioned
.

Answer: d
Explanation: Maskants can be applied to work piece, by the above mentioned means.

19. State whether the following statement is true or false regarding maskants.
“After etching, maskants should be removed easily and inexpensively.”
a) True
b) False
.

Answer: a
Explanation: After etching is done, maskants should be removed easily by inexpensive means.

20. In maskant application, photo-resist masks ensure which of the following advantages?
a) High accuracy
b) Ease of repetition
c) Ease of modification
d) All of the mentioned
.

Answer: d
Explanation: We will have the advantages which are mentioned above, if we use photo resist masking.

21. Which of the tolerance values are obtained, when we use cut and peel mask method for maskant?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
.

Answer: d
Explanation: Tolerance value of ± 0.179 mm, will be obtained, when we use cut and peel mask method.

22. Which of the tolerance values are obtained, when we use silk-screen resist method for maskant?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
.

Answer: c
Explanation: Tolerance value of ± 0.077 mm, will be obtained, when we use silk screen resist method.

23. Which of the tolerance values are obtained, when we use photo resist method for maskant application?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
.

Answer: a
Explanation: Tolerance value of ± 0.013 mm, will be obtained, when we use photo resist method.

24. Which of the following, are the main uses of etchants applied in Chemical milling?
a) Good surface finish
b) Uniform material removal
c) Control intergranular attack
d) All of the mentioned
.

Answer: d
Explanation: In CHM, etchants are used for the above mentioned factors.

25. State whether the following statement is true or false about etchants.
“Etchants are used for controlling H2 absorption in case of Ti alloys.”
a) True
b) False
.

Answer: a
Explanation: Etchants control the H2 absorption in Ti alloys.

26. Scribing plates are used to define, which of the following parameters in Chemical milling?
a) Areas to be exposed
b) Volumes to be exposed
c) Areas not to be exposed
d) Volumes not to be exposed
.

Answer: a
Explanation: Scribing plates defines the areas that are to be exposed for removal of material.

27. Which of the following are can be used as guides for scribing process in Chemical milling?
a) Layout lines
b) Simple templates
c) Fibre glass
d) All of the mentioned
.

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
d) All of the mentioned
.

Answer: d
Explanation: The accessories mentioned above are included in the tooling of Chemical milling.

29. Which of the following come under process parameters of Chemical milling?
a) Reagent type
b) Concentration
c) Operating temperature
d) All of the mentioned
.

Answer: d
Explanation: All the parameters mentioned above, are different process parameters required for Chemical milling.

30. State whether the following statement is true or false about Chemical milling.
“Maskants, applied on work pieces, are not responsible for CHM process.”
a) True
b) False
.

Answer: b
Explanation: Maskants are also responsible for process to take place in Chemical milling.

31. To machine high quality parts using CHM, which of the following need not be necessary?
a) Heat treatment of work piece
b) Grain size of work piece
c) Frequency of vibrations
d) Range of work pieces
.

Answer: c
Explanation: To machine high qualities products vibrational frequency is not necessary in CHM.

32. The process parameters will have direct impact on which of the following factors?
a) Etch factor
b) Machining rate
c) Production tolerance
d) All of the mentioned
.

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.
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34. Which of the following, are the general materials used for maskant application?
a) Neoprene
b) Poly vinyl chloride
c) Polyethylene
d) All of the mentioned
.

Answer: d
Explanation: All the materials mentioned above, can be used as maskant materials.

35. State whether the following statement is true or false regarding MRR.
“The rate of material removal, does not depend on uniformity of the solution temperature.”
a) True
b) False
.

Answer: b
Explanation: Material removal rate also depends on uniformity of the solution temperature.

36. On which of the following factors, MRR will not be depend on?
a) Chemical uniformity
b) Metallurgical uniformity
c) Frequency uniformity
d) Temperature uniformity
.

Answer: c
Explanation: Chemical milling is independent of frequency distribution.

37. Castings having a larger grain size, will show how much surface roughness value?
a) Very low
b) Low
c) Medium
d) High
.

Answer: d
Explanation: In castings, as grain size increases, surface roughness increases.

38. Which of the following materials have the highest machining rate and best surface quality?
a) Rolled metal sheets
b) Thick metal plates
c) Polymeric plates
d) Plastic sheets
.

Answer: a
Explanation: Rolled metal sheets will have highest machining rate and surface quality in CHM.

39. For softer materials, which type of etching rates are obtained?
a) Very low
b) Low
c) Medium
d) High
.

Answer: b
Explanation: In Chemical milling, softer materials need low etching rates.

40. For harder materials, which of the following etching rates are obtained?
a) Very low
b) Low
c) Medium
d) High
.

Answer: d
Explanation: In Chemical milling, harder materials need higher etching rates.

41. State whether the following statement is true or false about etching rates.
“As the etching rate increases, low surface roughness values occur.”
a) True
b) False
.

Answer: a
Explanation: High etching rates result in low surface roughness values.

42. Which of the following are necessary for best surface quality in Chemical milling?
a) Fine grain size and homogenous metallurgy
b) Coarse grain size and heterogeneous metallurgy
c) Fine grain size and heterogeneous metallurgy
d) Coarse grain size and homogenous metallurgy
.

Answer: a
Explanation: In CHM, for best surface quality, fine grain size and homogenous metallurgical work piece must be required.

43. Which of the following are the factors, on which, surface finish depends?
a) Grain size
b) Heat treatment
c) Induced stresses
d) All of the mentioned
.

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
.

Answer: b
Explanation: Using CHM, surface imperfections cannot be eliminated.

46. Which type of etching rate, mentioned below, produces low surface roughness?
a) Very low
b) Low
c) Medium
d) High
.

Answer: d
Explanation: In Chemical milling, high etching rate produces low surface roughness values and tolerances.

47. The depth of cut tolerances increases when machining ____________ depths at high machining rates.
a) Very smaller
b) Smaller
c) Medium
d) Larger
.

Answer: d
Explanation: In Chemical milling, tolerance increases when machining depth increases.

48. What is the value of etching rate, which can be achieved using Chemical milling?
a) 0.001 mm/min
b) 0.025 mm/min
c) 0.050 mm/min
d) 0.075 mm/min
.

Answer: c
Explanation: While we use Chemical milling etch rates of around 0.025 mm/min are achieved.

49. What are the tolerance values achieved in Chemical milling, which depend on work piece material and depth of cut?
a) ± 10%
b) ± 20%
c) ± 30%
d) ± 40%
.

Answer: a
Explanation: Tolerances of ± 10% of cut width are achieved using CHM.

50. For what value of machining depths, surface roughness sharply increases with depth of cut?
a) <100 µm
b) <200 µm
c) <300 µm
d) <400 µm
.

Answer: b
Explanation: For material depths <200 µm, surface roughness increases with depth of cut.

51. What is the value of surface roughness, which is generally obtained using Chemical milling?
a) 0.01 – 0.08 µm
b) 0.1 – 0.8 µm
c) 1 – 8 µm
d) 10 – 80 µm
.

Answer: b
Explanation: Surface roughness obtained when general conditions are applied, is between 0.1 – 0.8 µm.

52. What is the value of surface roughness, when special conditions are applied?
a) 0.001 – 0.025 µm
b) 0.025 – 0.05 µm
c) 0.05 – 0.075 µm
d) 0.075 – 0.1 µm
.

Answer: b
Explanation: Surface roughness obtained when special conditions are applied, is between 0.025 – 0.05 µm.

53. Which of the following can be easily removed using Chemical milling process?
a) TiO2 layer
b) Decarburized layer
c) Recast structure
d) All of the mentioned
.

Answer: d
Explanation: All the layers mentioned above, can be removed using Chemical milling.

54. State whether the following statement is true or false about Chemical milling.
“CHM can also affect mechanical properties, if they differ from surface layer to base metal.”
a) True
b) False
.

Answer: a
Explanation: Chemical milling can affect the mechanical properties of the machined parts if they are different at surface layers and base metal.

55. What are the advantages when we use Chemical milling process?
a) Weight reduction
b) No burrs
c) No stresses
d) All of the mentioned
.

Answer: d
Explanation: All the advantages mentioned above, can be obtained using Chemical milling process.

56. Weight reduction is possible, on which type of contours?
a) Very simple
b) Simple
c) Complex
d) None of the mentioned
.

Answer: c
Explanation: Weight reduction can be possible using Chemical milling, on complex contours, compared to conventional machining.

57. Simultaneous material removal using Chemical milling, results in which of the following?
a) Improves productivity
b) Reduces wrapping
c) Minimizing part distortion
d) All of the mentioned
.

Answer: d
Explanation: All the factor mentioned above occur, when we use Chemical milling for material removal.

58. State whether the following statement is true or false regarding the advantages of CHM.
“As there are no stresses induced, machining of delicate parts is possible.”
a) True
b) False
.

Answer: a
Explanation: In CHM, no stresses are induced, which makes machining of delicate parts easier.

59. Which type of taper can be achieved, using Chemical milling, on contours?
a) Discontinuous
b) Continuous
c) Periodic
d) None of the mentioned
.

Answer: b
Explanation: Using Chemical milling, a continuous taper, on contours can be achieved.

60. State whether the following statement is true or false regarding the advantages?
“Capital cost of equipment, for machining large components, is relatively high.”
a) True
b) False
.

Answer: b
Explanation: Capital cost of equipment, is relatively low for machining large components.

61. Which of the following, are the other advantages of CHM?
a) Design changes
b) Less skilled operator
c) Minor tooling costs
d) All of the mentioned
.

Answer: d
Explanation: All of the advantages mentioned above, are obtained using CHM.

62. Good surface quality and absence of burr eliminates which of the following?
a) Cutting operations
b) Finishing operations
c) Drilling operations
d) None of the mentioned
.

Answer: d
Explanation: Absence of burrs and good surface quality eliminates finishing operations in CHM.

63. State whether the following statement is true or false about advantages.
“Extensive web areas and decorative finishes are not possible using CHM.”
a) True
b) False
.

Answer: b
Explanation: Decorative finishes are obtained when we use CHM.

64. What are the values of scrap rates obtained in Chemical milling?
a) 1%
b) 3%
c) 5%
d) 7%
.

Answer: b
Explanation: Low scrapes rates around 3% are obtained when we use the Chemical milling process.

65. Which of the following are the limitations of Chemical milling process?
a) Disposal of chemicals
b) Limited scribing accuracy
c) Surface imperfections
d) All of the mentioned
.

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
.

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
d) All of the mentioned
.

Answer: d
Explanation: All the factors mentioned above, are main disadvantages for different processes in CHM.

68. Which type of metallurgical surfaces are needed in Chemical milling process?
a) Homogenous
b) Heterogeneous
c) Mixture
d) None of the mentioned
.

Answer: a
Explanation: Metallurgic homogenous surfaces are needed for chemical milling to take place.

69. Porous castings yield, which type of surfaces in Chemical milling process?
a) Uniform surfaces
b) Even surfaces
c) Uneven surfaces
d) None of the mentioned
.

Answer: c
Explanation: As there are porous castings, there would be pores on the surface which lead to uneven surfaces.
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70. State whether the following statement regarding the limitations of CHM.
“Welded areas etch, at a rate that is same as base metal.”
a) True
b) False
.

Answer: b
Explanation: Welded areas etch at a different rate, when compared to that of base material.

71. The absence of residual stresses on the chemically machined surfaces can produce __________ strength.
a) Favorable fatigue
b) Unfavorable fatigue
c) Constructive fatigue
d) None of the mentioned
.

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
c) Infinite
d) None of the mentioned
.

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
d) All of the mentioned
.

Answer: d
Explanation: Hydrogen pick up, intergranular attack are some other limitations in Chemical milling process.

74. Which of the following is not a limitation of Chemical milling process?
a) Steep tapers not practical
b) Low scrap rates
c) Less scribing accuracy
d) Deep narrow cuts
.

Answer: b
Explanation: Low scrap rates are possible in Chemical milling, which is an advantage to the process.

75. Which of the following metals can be machined using the Chemical milling process?
a) Copper
b) Zinc
c) Steel
d) All of the mentioned
.

Answer: d
Explanation: Zinc, copper, lead, and nickel are some of the metals that can be chemically machined.

76. What is the range, between which, the depth of cut in Chemical milling varies?
a) 0.13 – 0. 84 mm
b) 0.93 – 1.56 mm
c) 2.54 – 12.27 mm
d) 13.3 – 104.56 mm
.

Answer: c
Explanation: Practically, depth of cut in Chemical milling range between 2.54 – 12.27 mm.

77. Which of the following non-metallic materials can be machined using the Chemical milling process?
a) Plastics
b) Glass
c) Ceramics
d) All of the mentioned
.

Answer: d
Explanation: Non-metallic materials such as glass, ceramics and plastics can also be machined using Chemical milling process.

78. 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
d) None of the mentioned
.

Answer: a
Explanation: Shallow cuts in large thin sheets helps in reducing the weight, especially in aerospace industries.

79. How many designs can be machined from the same sheet in Chemical milling?
a) Only one
b) Two
c) Three
d) Multiple
.

Answer: d
Explanation: In Chemical milling, multiple designs can b machined on a large thin sheet depending upon the size of the designs.

80. CHM is used to thin out walls, web and ribs of parts that have been produces by which of the following processes?
a) Forging
b) Casting
c) Sheet metal forming
d) All of the mentioned
.

Answer: d
Explanation: CHM is used for applications mentioned above of the parts, which are formed by casting, forging and sheet metal forming processes.

81. Removal of sharp burrs come under which application of Chemical milling process?
a) Deep cuts
b) Multiple part machining
c) Improving surface characteristics
d) None of the mentioned
.

Answer: c
Explanation: Removal of sharp burrs improve the surface characteristics of parts machined using Chemical milling.

82. 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
d) All of the mentioned
.

Answer: d
Explanation: The defects on surfaces mentioned above, can be eliminated using Chemical milling process.

83. 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.

84. State whether the following statement is true or false regarding the applications of CHM.
“Removal of thin surfaces, prior to inspection, is done for detection of hidden defects.”
a) True
b) False
.

Answer: a
Explanation: Removal of thin surfaces is done to detect the hidden defects in surfaces using CHM.

85. In advanced machining process, what is the full form of PCM?
a) Photochemical manufacturing
b) Photochemical machining
c) Photo crystalline manufacturing
d) Photo crystalline machining
.

Answer: b
Explanation: Full form of PCM in advanced machining processes is Photochemical milling.

86. In this method, which of the following techniques are used to apply the maskant on the machining surface?
a) Photographic techniques
b) Cut and peel masking
c) Silkscreen resist technique
d) None of the mentioned
.

Answer: a
Explanation: Maskant is applied on the machining surface using photographic techniques in PCM.

87. What is the similarity between normal Chemical milling process and Photo chemical milling?
a) Both use chemicals
b) Maskant application method
c) None of the mentioned
d) All of the mentioned
.

Answer: a
Explanation: Both method are similar in one property i.e.., they both use chemicals.

88. In some cases, Photochemical milling can also be called as ______________
a) Photo chemical blasting
b) Photo chemical blanking
c) Photo chemical drilling
d) Photo chemical erosion
.

Answer: b
Explanation: In some cases flat, thin gauge complex parts can be machined, this process is known as Photochemical Blanking (PCB).

89. Photo chemical blanking can be used to machine the parts to high precision, up to which of the following thickness values?
a) 0.001 – 0.007 mm
b) 0.007 – 0.012 mm
c) 0.013 – 1.503 mm
d) 1.612 – 2.125 mm
.

Answer: c
Explanation: PCB can be used to machine parts of thickness 0.013 – 1.50 mm to high precision.
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90. State whether the following statement is true or false regarding Photochemical milling.
“Unlike that of CHM, PCM can also be used to create parts.”
a) True
b) False
.

Answer: a
Explanation: In CHM original parts manufactured in other processes are machined. Unlike that case, in PCM parts can be created from thin sheets using maskants.

91. In case of photochemical milling that use using lettering and graphics for surface etching, what will be the depth of surface etched?
a) Very deep
b) Up to certain depth
c) Half-way
d) None of the mentioned
.

Answer: b
Explanation: Sometimes photochemical machining is used to surface-etch components with lettering or graphics, in which etchant works to only a certain depth.

92. When was the process, Photochemical milling is introduced to the machining environment?
a) 1920s
b) 1930s
c) 1950s
d) 1960s
.

Answer: d
Explanation: PCM was introduced to the machining industry in 1960s, as an offshoot of PCBs.

93. State whether the following statement is true or false regarding PCM.
“In PCM, etching depth does not depend on the time, a component is immersed in the chemical solution.”
a) True
b) False
.

Answer: b
Explanation: As in case of CHM, depth of etch in PCM depend upon the time of part immersed in chemical solution.

94. Which of the following processes does not come under Chemical machining processes?
a) Chemical milling
b) Photo forming
c) Photo chemical filling
d) Photo chemical blanking
.

Answer: b
Explanation: Photo forming is a process of electro plating metals over the mandrels which does not use chemical for material removal.

95. Which of the following is the first step in Photo chemical milling process?
a) Generation of photographic film
b) Etching the part
c) Removal of etchant
d) Photo resist stripping
.

Answer: a
Explanation: Generation of photographic film using CAD drawings is the first step in PCM.

96. What is the other name for photographic film generated in Photochemical milling?
a) Photo mask
b) Photo tool
c) Photo cover
d) Photo plate
.

Answer: b
Explanation: The photographic film generated using CAD drawings, which is also called as Photo tool.

97. What is the next step after generation of Photo-tool?
a) Chemical cleaning
b) Coating of photo tool
c) None of the mentioned
d) All of the mentioned
.

Answer: d
Explanation: After generation of photo-tool, it is applied to the chemically cleaned work surface.

98. What is the use of photo tool in Photochemical milling process?
a) Cleaning of work piece
b) Protection of surface against etching
c) Etching of part surface
d) None of the mentioned
.

Answer: b
Explanation: In PCM, photo tool is applied as coating which act as stencil resist that protect the surface from etching.

99. Where are the photo tools applied on the surface of the work piece material?
a) On the top
b) On the bottom
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: Photo tools are applied in pairs- one on the top and one on the bottom like sandwiching work piece between photo layers.
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100. The photo tool is exposed to which light source, in order to form a replica of image of the required geometry?
a) Infrared sources
b) Ultraviolet source
c) Normal light source
d) None of the mentioned
.

Answer: b
Explanation: Ultraviolet light sources are used to transfer the image of the required geometry on to the resist, precisely.

101. Which can be used as solutions which develop the photo resists in PCM?
a) Water
b) Alkaline solution
c) Hydrocarbons
d) All of the mentioned
.

Answer: d
Explanation: In PCM, the solutions mentioned above can be used to develop the photoresist films on the surfaces.

102. What is the next step after creating the photo tool and adhering it to work piece using UV light source?
a) Finishing
b) Etching
c) Rinsing and drying
d) None of the mentioned
.

Answer: b
Explanation: After the image is adhered to work piece, etching is done.

103. The right choice of etchant depend on, which of the following factors?
a) Rate of material removal
b) Etching depth
c) Cost and quality
d) All of the mentioned
.

Answer: d
Explanation: Etchant selection depends on cost, quality, etch depth and MRR rate.

104. After etching is done, what is the next step in Photochemical milling process?
a) Finishing
b) Rinsing and drying
c) Removal of protective layer
d) None of the mentioned
.

Answer: b
Explanation: After etching is done in PCM, the parts are rinsed and dried.

105. How are the protective layer coatings on the parts are removed?
a) Use of chemicals
b) Mechanical techniques with chemicals
c) None of the mentioned
d) All of the mentioned
.

Answer: d
Explanation: The protective layers are removed by the use of chemicals and by using mechanical techniques with chemicals.

106. Which of the following are the metals that can be machined using Photo chemical milling?
a) Aluminium
b) Copper
c) Nickel
d) All of the mentioned
.

Answer: d
Explanation: Copper, aluminium, zinc, steel, molybdenum, zirconium, titanium are some of the metals that can be machined using PCM.

107. Which of the following non-metallic materials that can be machined using PCM?
a) Glass
b) Ceramics
c) Some plastics
d) All of the mentioned
.

Answer: d
Explanation: The non-metallic materials mentioned above, can be machined using PCM.

108. Which of the following materials are excellent for Photochemical milling?
a) Brittle materials
b) Ductile materials
c) Elastic materials
d) None of the mentioned
.

Answer: a
Explanation: Brittle materials are excellent candidates for PCM, since they tend to break easily using traditional machining processes.

109. State whether the following statement is true or false about applications of PCM.
“Using PCM, very high tempered materials are machined easily.”
a) True
b) False
.

Answer: a
Explanation: PCM can be favourable for very high tempered and brittle materials unlike that of traditional machining, where they tend to break easily.

110. Which of the following are the typical applications of Photo chemical milling?
a) Production of signs
b) Production of labels
c) Fabrication of boxes and enclosures
d) All of the mentioned
.

Answer: d
Explanation: Using PCM, the above mentioned applications can be fulfilled.
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111. What is the value of thickness of work pieces to be used in PCM?
a) 0.001 – 0.003 mm
b) 0.013 – 1.50 mm
c) 1.50 – 2.35 mm
d) 2.50 – 3.33 mm
.

Answer: b
Explanation: The thickness value of work pieces in PCM range between 0.013 – 1.50 mm.

112. What type of work pieces must be used in Photochemical milling process?
a) Bent surfaces
b) Rolled surfaces
c) Flat surfaces
d) None of the mentioned
.

Answer: c
Explanation: The work pieces must be flat in order to carry on the PCM process.

113. Which of the following industries use PCM for different applications?
a) Electronic
b) Automotive
c) Telecommunication
d) All of the mentioned
.

Answer: d
Explanation: PCM has its applications in the industries such as electronics, automotive, telecommunication, computer, medical, aerospace and other industries.

114. Which of the following are the components that can be machined using PCM?
a) Filters and screens
b) Lead frames
c) Connectors and probes
d) All of the mentioned
.

Answer: d
Explanation: Typical components such as gaskets, lead frames, contacts, connectors, probes, filters and screens can be machined using PCM.

115. What is the cost per unit for low production volumes of complex designs using PCM?
a) Low
b) Medium
c) High
d) None of the mentioned
.

Answer: a
Explanation: Relatively low cost per unit is required in PCM, since tooling is inexpensive compared to that of traditional practices.

116. State whether the following statement is true or false regarding advantages of PCM.
“In PCM, lead times are large, when compared to that required for hard tooling using traditional means.”
a) True
b) False
.

Answer: b
Explanation: Lead times are small when compared to that required by processes that require hard tooling.

117. Which of the following factors can change the parameters of etch such as depth, size of hole etc.?
a) Time of etch
b) Type of etchant
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: Type of etchant used and time for etching can change the features such as hole size and depth of etch.

118. How much amount of burr is produced, when components are machined using PCM?
a) Small
b) Medium
c) Large
d) No burr
.

Answer: d
Explanation: Photochemical milling is a burr-free process i.e.., burr is not produced in this process.

119. Which of the following properties of materials are changed by using Photochemical milling?
a) Hardness of material
b) Ductility of material
c) Grain structure
d) None of the mentioned
.

Answer: d
Explanation: In PCM, material properties such as hardness, ductility and grain structure are not changed.

120. State whether the following statement is true or false regarding advantages of PCM.
“Patterns can be reproduced easily.”
a) True
b) False
.

Answer: a
Explanation: Patterns can be reproduced easily because tooling is made by photographic techniques.

121. In advanced machining processes, what is the full form of EP?
a) Electro plating
b) Electro polishing
c) Electron pocketing
d) Electrical punching
.

Answer: b
Explanation: Full form of EP is Electro-polishing in advanced machining processes.

122. When was the process Electro polishing introduced to the advanced machining processes?
a) 1918
b) 1922
c) 1935
d) 1943
.

Answer: c
Explanation: Electropolishing was introduced to world in the year 1935, when Cu and Zn were successfully electropolished by Germans.

123. How is the material removed in Electropolishing process?
a) Anodic dissolution
b) Cathodic dissolution
c) Chemical corrosion
d) Mechanical erosion
.

Answer: a
Explanation: Material in Electropolishing is removed by anodic dissolution process.

124. State whether the following statement is true or false regarding EP process.
“Electropolishing is same as electro plating.”
a) True
b) False
.

Answer: b
Explanation: Electropolishing is the opposite of electroplating.

125. In the following terminals, part to be finished acts as which terminal in EP process?
a) Anode
b) Cathode
c) Neutral
d) None of the mentioned
.

Answer: a
Explanation: As this process is opposite to that of Electro plating, part to be finished is the anode in EP.

126. Which of the following come under the components of EP process?
a) Electrolyte solution
b) Dc power supply
c) Work piece
d) All of the mentioned
.

Answer: d
Explanation: The EP process components include DC power supply, electrolyte, electrically charged terminals, of which, one of them is work piece.

127. Electrolytic solution is a mixture of which of the following?
a) Insoluble salts
b) Several acids
c) All of them mentioned
d) None of the mentioned
.

Answer: c
Explanation: Electrolytic solution is a mixture of several acids and insoluble salts.

128. What amount of current density can be used for Electropolishing to take place?
a) Very low
b) Low
c) Optimum
d) Very high
.

Answer: b
Explanation: Limiting amount of current should be used in EP process for anodic dissolution.

129. Which of the following takes place if the current density used is relatively high?
a) Smoothing
b) Finishing
c) Oxygen evolution
d) All of the mentioned
.

Answer: c
Explanation: If the current level increases beyond the limiting value, pitting takes place due to gas evolution.

130. More anodic dissolution takes place at which part of the surface of the work piece?
a) Peaks
b) Valleys
c) Troughs
d) None of the mentioned
.

Answer: a
Explanation: Anodic dissolution is high at peaks when compared to valleys on the surface of the work pieces.

131. State whether the following statement is true or false about EP process.
“In EP, produced surface possess true crystalline structure without distortion.”
a) True
b) False
.

Answer: a
Explanation: In Electropolishing, the produced surface possess true crystalline structure without distortion, unlike that of cold working as in mechanical finishing.

132. Surfaces produced in Electropolishing process possess which of the qualities?
a) Bright
b) Clean
c) Microscopically smooth
d) All of the mentioned
.

Answer: d
Explanation: Surfaces produced in EP becomes clean, bright and microscopically smooth.

133. How much amount of properties of bulk material, are possessed by the finished part in EP?
a) Negligible amount
b) Only some properties
c) All properties
d) None of the mentioned
.

Answer: c
Explanation: The part machined using EP process, possess true properties of the bulk material.

134. State whether the following statement is true or false regarding EP.
“Fine direction lines are left in EP, like that of abrasive polishing.”
a) True
b) False
.

Answer: b
Explanation: Unlike that of abrasive polishing, fine direction lines are not produced.

135. Of the following material removal mechanisms, material is removed by which one in EP?
a) Electrode dissolution
b) Corrosion
c) Abrasion
d) Erosion
.

Answer: a
Explanation: Anodic dissolution takes place in Electropolishing process.

136. Which of the following come under the process parameters of the Electropolishing?
a) Work piece material and condition
b) Current density
c) Applied voltage
d) All of the mentioned
.

Answer: d
Explanation: The process parameters of Electropolishing include current density, applied voltage, acid type, temperature original surface roughness, work piece condition and material.

137. Current density of the EP process generally varies between which of the following values?
a) 0.0001 – 0.001 A/cm2
b) 0.005 – 1.8 A/cm2
c) 1.9 – 2.532 A/cm2
d) 3.523 – 4.23 A/cm2
.

Answer: b
Explanation: Generally current density value used in EP process vary between 0.005 – 1.8 A/cm2.

138. Which of the following are the work piece materials that can be machined using Electropolishing?
a) Carbon steel
b) Alpha brass
c) Phosphor bronze
d) All of the mentioned
.

Answer: d
Explanation: Different work piece materials that can be machined using EP are carbon steels, stainless steels, copper, alpha brass, nickel, phosphor bronze, aluminium, magnesium etc.

139. Which of the following electrolyte, can be used commonly for stainless steel, Cu, Ni and Mg?
a) HCLO4
b) H2PO4
c) H2SO4
d) HNO3
.

Answer: b
Explanation: H2PO4 is a common electrolyte used in the machining of Cu, Ni, Mg.
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140. What is the electrolytic solution’s temperature when stainless steel is machined?
a) 50o C
b) 80o C
c) 120o C
d) 150o C
.

Answer: b
Explanation: Temperature of electrolytic solution used for machining stainless steel is 80o C.

141. State whether the following statement is true or false regarding process parameters of EP.
“In EP, process parameters have a direct impact on surface quality and productivity of process.”
a) True
b) False
.

Answer: a
Explanation: In Electropolishing, parameters have a direct impact on quality of surface and productivity.

142. For machining of Cu material which of the following can be used as electrolytes?
a) H2PO4
b) H2PO4 and Na2CrO4
c) HCLO4
d) HNO3
.

Answer: a
Explanation: For Cu material electrolyte used in EP process is H2PO4.

143. In the following types of voltage, which one best suites EP process?
a) Randomly Fluctuating
b) Constant
c) Periodically fluctuating
d) None of the mentioned
.

Answer: b
Explanation: For the machining to take place in Electropolishing process, voltage should be correct and constant.

144. State whether the following statement is true or false regarding process parameters of EP.
“In EP, high current densities are used for anodic dissolution.”
a) True
b) False
.

Answer: b
Explanation: In Electropolishing, limited current densities are used for anodic dissolution.

145. For economical and high quality Electropolishing, which of the following materials are used?
a) Cold rolled metals
b) Hot flat metals
c) Hot plastics
d) All of the mentioned
.

Answer: a
Explanation: Cold rolled metals are the most important materials for economical and high quality polishing.

146. State whether the following statement is true or false about applications of EP.
“In EP, cast items do not maintain the texture of sand mold.”
a) True
b) False
.

Answer: b
Explanation: Cast items usually maintain the texture of sand mold since they have coarse grains and include alloying elements.

147. Which of the following cannot be removed by using Electropolishing process?
a) Scales
b) Distortion
c) Coarse texture
d) Burrs
.

Answer: c
Explanation: Coarse texture cannot be removed using Electropolishing as they produce rough surfaces.

148. Electropolishing prepares surfaces for which of the following processes?
a) Electron Beam machining
b) Electro plating
c) Laser beam machining
d) Magnetic Abrasive machining
.

Answer: b
Explanation: EP prepares surfaces for electroplating, which creates an opportunity for best adherence.

149. For which of the following components, polishing can be done using EP?
a) Electrical conduits
b) Outlet boxes
c) Medical equipment
d) All of the mentioned
.

Answer: d
Explanation: Polishing light fixtures of electrical conduits, outlet boxes, and medical, surgical, and food processing equipment.

150. State whether the following statement is true or false regarding the applications of EP.
“Using Electropolishing, deburring and breaking sharp edges can be done.”
a) True
b) False
.

Answer: a
Explanation: Deburring and breaking sharp edges obtained from hand filing, grinding and honing of tools.

151. Electropolishing removes scales and distortions that are produces by which of the processes below?
a) Annealing
b) Nitriding
c) Carburizing
d) All of the mentioned
.

Answer: d
Explanation: Scales and distortions produced by annealing, carburizing, nitriding, welding and soldering can be removed using EP.

152. State whether the following statement is true or false about applications of EP.
“In EP, removal of hardness and stressed surface layers, reduces life of parts.”
a) True
b) False
.

Answer: b
Explanation: Removal of hardness and stressed surface layers improves the surface life of part.

153. Polishing of how many parts can be done using Electropolishing?
a) One part
b) Two parts
c) Multiple parts
d) None of the mentioned
.

Answer: c
Explanation: Multiple parts can be polished simultaneously using EP, depending upon the size of parts.

154. Electropolishing cannot cover up which type of defects?
a) Burrs on surfaces
b) Scales and distortions
c) Non-metallic inclusions
d) Metallographic examination
.

Answer: c
Explanation: Seams and non-metallic inclusions are some defects which cannot be covered up using EP.

155. Which of the following is a limitation of EP process?
a) Rough scratches removal
b) Scales removal
c) Distortions removal
d) Burr removal
.

Answer: a
Explanation: In EP, rough scratches cannot be removed even by considerable amount of process.

156. Metals containing which of the following chemicals will be troublesome in EP process?
a) Silicon
b) Lead
c) Sulphur
d) All of them mentioned
.

Answer: d
Explanation: All the elements mentioned above, if present in metals, will be troublesome in EP process.

157. State whether the following statement is true or false regarding the limitations of EP.
“In EP, base metal condition does not affect the process.”
a) True
b) False
.

Answer: b
Explanation: Base metal condition affects the process of EP.

158. Which of the following defects lead to poor electropolishing of the surfaces?
a) Improper annealing
b) Non-metallic inclusions
c) Over pickling
d) All of the mentioned
.

Answer: d
Explanation: Non-metallic inclusions, over pickling, large grain size, direction roll marks, improper cold reduction leads to poor electro polishing.

159. Electropolishing is more suited for, removal of which of the following defects?
a) Small scratches
b) Imperfections
c) Smoothing
d) All of the mentioned
.

Answer: d
Explanation: Small scratches and imperfections can be easily removed when compared to that of rough scratches.

Electrochemical Processes

1. In advanced machining processes, what is the full form of ECM?
a) Electrochemical manufacturing
b) Electrochemical milling
c) Electrochemical machining
d) Electrochemical masking
.

Answer: b
Explanation: In advanced machining processes, the full form of ECM is Electrochemical machining.

2. In the following scientists, who was the one to introduce first patent on ECM?
a) Balamuth
b) Steve O Flawer
c) Gusseff
d) McGeough
.

Answer: c
Explanation: Gusseff was the one, who introduced the first patent on ECM in 1929.

3. When was the first significant development of ECM occurred?
a) 1920s
b) 1930s
c) 1950s
d) 1960s
.

Answer: c
Explanation: After the first patent in 1929, the first development of ECM was done in 1950s.

4. Which of the following material removal mechanisms is implemented by ECM?
a) Mechanical abrasion
b) Electrochemical dissolution
c) Chemical corrosion
d) Mechanical erosion
.

Answer: b
Explanation: In ECM, material is removed by electrochemical dissolution.

5. Electrolysis occur when which of the following takes place between electrodes?
a) Electric current flow
b) Electron flow
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: When there is an electron flow there is current flow in the opposite direction. For electrolysis to take place there should be flow of current between electrodes.
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6. The system which consists of electrolytic solution and electrodes can be referred to as ____________
a) Electrolytic cell
b) Electrode system
c) Electrolytic system
d) Electrode cell
.

Answer: a
Explanation: The system of electrodes and electrolytic solution is referred as electrolytic cell.

7. The chemical reactions occurring at electrodes are called with, which of the following names?
a) Anodic reactions
b) Cathode reactions
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: Chemical reactions occurring at electrodes are called as anodic or cathodic reactions.

8. Amount of mass dissolved is directly proportional to which of the following quantities?
a) Amount of electricity
b) Frequency of vibrations
c) Amplitude of oscillations
d) All of the mentioned
.

Answer: a
Explanation: Amount of mass dissolved is directly proportional to amount of electricity and also substances’ chemical equivalent.

9. 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.

10. 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.

11. What are the values of voltages used in ECM?
a) 1 to 8 V
b) 10 to 30 V
c) 40 to 80 V
d) 90 to 110 V
.

Answer: b
Explanation: Low voltages, ranging between 10 to 30 V are used in Electrochemical machining.

12. How does the current pass between the two electrodes in ECM?
a) Electrolytic solution
b) Direct contact of electrodes
c) All of the mentioned
d) None of the mentioned
.

Answer: a
Explanation: Current passes through the solution of electrolyte, which fills the gap between the electrodes.

13. What is the value of velocity with which, electrolyte flows in the inter electrode gap?
a) >1 m/s
b) >3 m/s
c) >5 m/s
d) >10 m/s
.

Answer: c
Explanation: The velocity of the electrolytic solution must be greater than 5 m/s, in order to intensify the mass and charge transfer.

14. Of the following, electrolyte removes which of the dissolution products?
a) Metal hydroxides
b) Heat
c) Gas bubbles
d) All of the mentioned
.

Answer: d
Explanation: Electrolyte removes the dissolution products such as metal hydroxides, heat and gas bubbles formed in the inter electrode gap.

15. 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
b) False
.

Answer: a
Explanation: When P.D (potential difference) is applied, different reactions occur at anode and cathode.

16. Which of the following reactions takes place at the electrodes?
a) Generation of hydrogen
b) Dissolution of iron
c) Dissolution of NaCl
d) All of the mentioned
.

Answer: d
Explanation: All the reactions mentioned above, take place at different electrodes in ECM.

17. Which of the following reaction takes place at anode?
a) Generation of hydrogen
b) Dissolution of iron
c) Generation of hydroxyl ions
d) None of the mentioned
.

Answer: b
Explanation: At anode, dissolution of Fe takes place in the process of ECM.

18. Which of the following reactions take place at cathode?
a) Generation of hydrogen
b) Dissolution of iron
c) Dissolution of NaCl
d) All of the mentioned
.

Answer: a
Explanation: At cathode, generation of hydrogen takes place in the process of ECM.

19. Positively charged particles (cations) move towards which electrode?
a) Anode
b) Cathode
c) Anode & Cathode
d) None of the mentioned
.

Answer: b
Explanation: Positively charge particles are directed towards the cathode, which is negatively charged.

20. Negatively charged particles (anions) move towards which electrode?
a) Anode
b) Cathode
c) Anode & Cathode
d) None of the mentioned
.

Answer: a
Explanation: Negatively charged particles are directed towards the anode, which is positively charged.

21. Which of the following come under the main components of ECM?
a) Feed control system
b) Work piece holding devices
c) Electrolyte supply system
d) All of the mentioned
.

Answer: d
Explanation: The main components of Electro chemical machining include feed control system, electrolyte supply system, power supply unit, work piece holding devices.

22. Feed control system is responsible for which action in ECM?
a) Giving feed to tool
b) Electrolyte supply
c) Power supply
d) None of the mentioned
.

Answer: a
Explanation: Feed control system is used for feeding the tool at constant rate during equilibrium machining.

23. In ECM equipment, what is the role of electrolyte supply system?
a) Giving feed to tool
b) Electrolyte supply
c) Power supply
d) None of the mentioned
.

Answer: b
Explanation: As the name itself indicates, electrolyte supply system is used to supply the electrolyte required for anodic dissolution.

24. What is the role of power supply unit in ECM equipment?
a) Giving feed to tool
b) Electrolyte supply
c) Power supply
d) None of the mentioned
.

Answer: c
Explanation: In ECM, power supply unit is used to supply the machine current at constant dc voltage.

25. For large size machining, which type of facilities are used in ECM?
a) Semi-automated facilities
b) Automated facilities
c) Automated & Semi-automated facilities
d) None of the mentioned
.

Answer: c
Explanation: Automated and semi-automated facilities are used for large size machining.
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26. Electrolyte supply system should concentrate on which of the following factors?
a) Pressure
b) Supply rate
c) Temperature
d) All of the mentioned
.

Answer: d
Explanation: Electrolyte supply system should supply electrolyte at a given rate, temperature and pressure.

27. For high strength or rigidity, which type of coatings are recommended for metals?
a) Other metal coatings
b) Non-metallic coatings
c) All of the mentioned
d) None of the mentioned
.

Answer: b
Explanation: For high strength and rigidity, non-metallic coatings are recommended for metals.

28. What is the value of voltage that the power supply unit supplies for ECM?
a) 0.01 to 1 V
b) 2 to 30 V
c) 50 to 80 V
d) 100 to 160 V
.

Answer: b
Explanation: Voltage supply required for ECM ranges between 2 to 30 V.

29. Between which of the following values, does the current range?
a) 0.002 to 0.01 A
b) 0.01 to 10 A
c) 50 to 10000 A
d) 105 to 106 A
.

Answer: c
Explanation: In Electrochemical machining, current value ranges between 50 to 10000 A.

30. What are the values of current densities used in ECM?
a) 0.1 to 2 A/cm2
b) 5 to 500 A/cm2
c) 600 to 1000 A/cm2
d) 1200 to 2800 A/cm2
.

Answer: b
Explanation: Current density values in ECM range between 5 to 500 A/cm2.

31. Which type of adjustment is to be done for gap voltages?
a) Continuous adjustment
b) Discontinuous adjustment
c) Periodic adjustment
d) All of the mentioned
.

Answer: a
Explanation: In ECM, usually continuous adjustment of gap voltage is required.

32. Compared to the tool used in ECM, how should be the work piece size?
a) Greater than
b) Smaller than
c) Same as tool
d) None of the mentioned
.

Answer: a
Explanation: By an oversize, work piece size is expected to be greater than tool size.

33. Which of the following factors are used to determine the tool geometry?
a) Required shape
b) Electrical conductivity
c) Tool feed rate
d) All of the mentioned
.

Answer: d
Explanation: For determining a tool geometry we must specify some factors such as the required shape of the surface, tool feed rate, gap voltage, electrochemical machinability of the work material, electrolyte conductivity, and both electrodes’ polarization voltages.

34. Which of the following are the simplest methods for applying the insulation on tools?
a) Spraying
b) Dipping
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: In ECM, dipping or spraying are the simplest methods for insulating the tools.

35. State whether the following statement is true or false regarding the tools of ECM.
“With computer integrated manufacturing (CIM), cathodes are produced at high costs and less accurately.”
a) True
b) False
.

Answer: b
Explanation: Using CIM, cathodes are produced at low costs and more accurately.

36. What are the main functions of electrolyte in Electrochemical machining?
a) Conduct machining current
b) Removal of debris
c) Maintaining constant temperature
d) All of the mentioned
.

Answer: d
Explanation: Main functions of electrolyte are conducting machine current, removing the debris, carrying away the heat, maintaining constant temperature.

37. Electrolytic solution should ensure which type of anodic dissolution?
a) Uniform
b) Non-uniform
c) Low speed
d) None of the mentioned
.

Answer: a
Explanation: Uniform and high speed anodic dissolution must be ensured by the electrolyte.

38. 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.

39. Which type of electrical conductivity is necessary for electrolytic solution?
a) Low
b) Medium
c) High
d) None of the mentioned
.

Answer: c
Explanation: High electrical conductivity is needed for electrolytic solution in ECM.

40. What are the other features of electrolytic solution in ECM?
a) Non toxic
b) Less erosive
c) Less viscous
d) All of the mentioned
.

Answer: d
Explanation: Electrolytic solution should be nontoxic, less viscous and less erosive.

41. How much should be the electrolytic solution?
a) Highly expensive
b) Inexpensive
c) All of the mentioned
d) None of the mentioned
.

Answer: b
Explanation: Electrolyte must be inexpensive and available at ease.

42. Which are the most common electrolytes used in Electrochemical machining?
a) Sodium chloride
b) Sodium nitride
c) Sodium hydroxide
d) All of the mentioned
.

Answer: d
Explanation: Electrolytes such as sodium chloride, sodium nitride, sodium hydroxide are some of the electrolytes used in ECM.

43. Selection of electrolyte does not depend on which of the following factors?
a) Work piece material
b) Dimensional tolerance
c) Heat affected zones
d) Machining productivity
.

Answer: c
Explanation: Selection of electrolyte depend up on work piece material, dimensional tolerance, machining productivity and surface finish required.

44. 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 45oC.

45. What must be the value of the pressure of electrolytic solution used in ECM?
a) 1 to 10 kPa
b) 10 to 80 kPa
c) 100 to 200 kPa
d) 300 to 400 kPa
.

Answer: c
Explanation: Value of pressure of electrolytic solution must range between 100 to 200 kPa.

46. What must be the value of velocity of the electrolytic solution?
a) 10 to 15 m/s
b) 25 to 50 m/s
c) 60 to 100 m/s
d) 120 to 200 m/s
.

Answer: b
Explanation: Typical velocity of the electrolytic solution must range between 25 to 50 m/sec.

47. Local metal removal rates are high at which gap locations mentioned below?
a) Small gap
b) Medium gap
c) Large gap
d) None of the mentioned
.

Answer: a
Explanation: Local metal removal rates are high at small gap locations in ECM.

48. When local metal removal rates are high, how will be the current density and current efficiency?
a) High
b) Medium
c) Low
d) Very low
.

Answer: a
Explanation: When the local metal removal rates are high then current density and efficiency are also high.

49. Current efficiency depends on which of the following in ECM?
a) Anodic material
b) Electrolyte
c) Anodic material & Electrolyte
d) None of the mentioned
.

Answer: c
Explanation: Current efficiency in ECM depend on electrolyte and anodic material used.

50. 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.

51. What is the approximate value of faraday’s constant?
a) 65,200 C
b) 53,800 C
c) 96,500 C
d) 85,600 C
.

Answer: c
Explanation: 1 faraday equals to approximately 96500 C.

52. In the following ratios of metal dissolved amounts, which one represent the current efficiency?
a) Observed to theoretical
b) Theoretical to observed
c) All of the mentioned
d) None of the mentioned
.

Answer: a
Explanation: In electrochemical machining, current efficiency is the ratio of observed amount of metal dissolved to the theoretical amount of metal dissolved.

53. Apparent current efficiency is due to which of the following factors?
a) Choice of wrong valence
b) Passivation of anodic surface
c) Gas evolution at anode
d) All of the mentioned
.

Answer: d
Explanation: Current efficiency may be apparent because of choice of wrong valence, passivation of anodic surface or gas evolution at anodic surface.

54. State whether the following statement is true or false regarding the working principles.
“In ECM, grain boundary attacks remove the grains through electrolytic forces.”
a) True
b) False
.

Answer: a
Explanation: In ECM, grain boundary attacks are the cause for removal of grains by electrolytic forces.

55. In ECM, gap increase proportional to which relation of time below?
a) Square of time
b) Square root of time
c) Cube of time
d) Cube root of time
.

Answer: b
Explanation: In Electrochemical machining, gap increases proportional to the square root of time.
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56. At constant feed rates what happens to gap thickness?
a) Increases
b) Decreases
c) Becomes constant
d) None of the mentioned
.

Answer: c
Explanation: At constant feed rate, work piece becomes stationary and thus the gap thickness becomes constant.

57. At constant gap thickness material removal becomes equal to feed rate. What is this gap called?
a) Equal gap
b) Equilibrium gap
c) Unique gap
d) Narrow gap
.

Answer: b
Explanation: When rate of material removal per unit area is same as feed rate, then corresponding thickness is called as equilibrium thickness indicated by ‘ye’.

58. If the gap thickness is greater than equilibrium thickness what will be MRR?
a) MRR is less than feed rate
b) MRR is greater than feed rate
c) MRR is equal to feed rate
d) None of the mentioned
.

Answer: a
Explanation: When gap thickness is greater than equilibrium thickness, MRR will be less than feed rate.

59. During ECM drilling, decrease in feed rates lead to which type of machining gaps?
a) Wider
b) Narrow
c) Small
d) None of the mentioned
.

Answer: a
Explanation: Decrease in feed rate lead to wider gap thickness in ECM drilling.

60. Too small gap causes which of the following effects?
a) Sparking
b) Short circuit
c) Sparking & Short circuit
d) None of the mentioned
.

Answer: c
Explanation: Sparking or short circuit occurs when the gap is too small.

61. 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.

62. Better surface finish and higher accuracy depend on which of the factors below?
a) Chemical composition of the electrolyte
b) Current density
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: Proper chemical composition of electrolyte and proper current density are responsible for better surface finish and accuracy.

63. For alloys, which type of electrolyte is used in ECM?
a) Single component
b) Double component
c) Multi component
d) Triple component
.

Answer: c
Explanation: Depending up on the elements in an alloy multi component electrolytes are used.

64. Nickel can be machined with 100% current efficiency, when current density value is ______________
a) 10 A/cm2
b) 25 A/cm2
c) 45 A/cm2
d) 80 A/cm2
.

Answer: b
Explanation: Nickel is a metal suggested by Khayry, which can be machined at 100% current efficiency, if current density is 25 A/cm2.

65. When the electrolyte flow is low, what happens to the current efficiency?
a) Increases
b) Decreases
c) Remains same
d) Increase and then decrease
.

Answer: b
Explanation: In ECM, if the electrolyte flow is low, current efficiency is reduced due to the accumulation of machining products within the gap.
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66. When machining Ti, in Nacl electrolyte, what values of current efficiencies are obtained?
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.

67. State whether the following statement is true or false about electrolyte in ECM.
“Machinability in ECM is enhanced, when electrolyte is heated.”
a) True
b) False
.

Answer: a
Explanation: Machinability is increased, when electrolyte is heated, as heating increases the specific conductivity of the electrolyte.

68. In practice, what must be the temperature of electrolyte used in ECM?
a) 10 – 20oC
b) 20 – 40oC
c) 60 – 80oC
d) 80 – 100oC
.

Answer: c
Explanation: Temperature of electrolyte used in ECM must not exceed 60 – 70oC.

69. What is the value of moderate level of pH of electrolyte used?
a) 1 – 2
b) 2 – 4
c) 4 – 10
d) All of the mentioned
.

Answer: c
Explanation: Moderate level of pH of electrolyte used in ECM range between 4 – 10.

70. What must be the working voltage in Electrochemical machining?
a) 10 V
b) 20 V
c) 30 V
d) 40 V
.

Answer: b
Explanation: The electrolytes in ECM employ a working voltage up to 20 V.

71. Surface roughness depend on which of the following quantities?
a) Crystallographic irregularities
b) Alloy composition
c) Distribution of current density
d) All of the mentioned
.

Answer: d
Explanation: Surface roughness of machined surface in ECM depend on crystallographic irregularities, alloy composition, current density distribution, dislocations and grain boundaries.

72. For a better surface finish, which type of current distribution is required?
a) Even
b) Uneven
c) Even & Uneven
d) None of the mentioned
.

Answer: a
Explanation: More even distribution of the current density leads to a better surface finish.

73. Between which values does the frontal gap’s surface roughness vary?
a) 0.02 to 0.13 µm
b) 0.30 to 1.90 µm
c) 1.93 to 2.64 µm
d) 2.73 to 4.26 µm
.

Answer: b
Explanation: Surface roughness varies between 0.30 to 1.9 µm for frontal gap area.

74. Between which values does the side gap’s surface roughness vary?
a) >1 µm
b) >3 µm
c) >5 µm
d) >7 µm
.

Answer: c
Explanation: Surface roughness value is 5 µm or more for side gap areas.

75. In Electrochemical machining, larger grain size causes which type of finish?
a) Smoother
b) Rougher
c) Finer
d) All of the mentioned
.

Answer: b
Explanation: In ECM, larger grains cause rougher finish than finer grains.

76. Which type of gap width is necessary for a higher degree of accuracy?
a) Very small
b) Small
c) Medium
d) High
.

Answer: b
Explanation: A small gap width represents a high level of accuracy. Very small gap width results in sparks and short circuits.

77. Accuracy of machining is affected by, which of the following factors?
a) Material
b) Gap voltage
c) Feed rate
d) All of the mentioned
.

Answer: d
Explanation: Accuracy of the process is affected by material equivalent, gap voltage, feed rate, etc.

78. Which properties of electrolyte does not affect the accuracy of the process?
a) Temperature
b) Concentration
c) Non-reactive
d) Pressure
.

Answer: c
Explanation: Electrolyte must be reactive in order to carry on the reactions that occur at the electrodes.

79. For high process accuracy, which of the following factors are needed?
a) High feed rate
b) High conductivity
c) High feed rate & High conductivity
d) None of the mentioned
.

Answer: c
Explanation: For a higher degree of accuracy, there must be high feed rates and highly conductive electrolytes.

80. Tool insulation that __________ the side machining action is needed in the process of ECM.
a) Limits
b) Enhances
c) Maintains
d) None of the mentioned
.

Answer: a
Explanation: Tool insulation is needed, which limits the machining of other sides of work piece.
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81. If the current density is high as required, what type of machining occurs?
a) Pitting
b) Polishing
c) Etching
d) All of the mentioned
.

Answer: b
Explanation: When the current density is relatively high as required, then polishing occurs.

82. What happens when the current density is low in ECM?
a) Pitting occurs
b) Etching occurs
c) Pitting & Etching occurs
d) None of the mentioned
.

Answer: c
Explanation: When current density is lower than optimum, then etching and pitting occurs which are undesired.

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

84. Passivation is done on electrolytes in order to form which of the following?
a) Passive layer on machined parts
b) Passive layer on cathode
c) Passive layer on machined parts & cathode
d) None of the mentioned
.

Answer: a
Explanation: Passivation is done on the electrolytes in order to form a passive film on machined parts.

85. If there is an increase in the electrolyte flow, what happens to the rate of film formation?
a) Increases
b) Decreases
c) Remains same
d) All of the mentioned
.

Answer: b
Explanation: An increase in electrolytic solution flow decreases the anodic product formation, which reduces the rate of film formation.

86. What are the typical dimensional tolerances for frontal gaps in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
.

Answer: c
Explanation: The dimensional tolerances obtained for frontal gaps are ± 0.130 mm.

87. What are the tolerance values for the side gap in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
.

Answer: d
Explanation: The dimensional tolerances obtained for side gaps are ± 0.25 mm.

88. 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
.

Answer: b
Explanation: The dimensional tolerances obtained by proper machining are ± 0.025 mm.

89. It is difficult to machine inner radii smaller than __________ and outer radii less than ________ in ECM.
a) 0.1 mm, 0.2 mm
b) 0.5 mm, 0.8 mm
c) 0.8 mm, 0.5 mm
d) 0.2 mm, 0.1 mm
.

Answer: c
Explanation: It is difficult to machine inner radii < 0.8mm and outer radii < 0.5mm.

90. What is the value of the overcut that is obtained using ECM?
a) 0.3 mm
b) 0.5 mm
c) 0.7 mm
d) 0.9 mm
.

Answer: b
Explanation: An overcut of 0.5 mm is obtained when machined using ECM.

91. If there is a change in the selected machining conditions, it will have impact on which of the following?
a) Process accuracy
b) Surface finish
c) Process accuracy & Surface finish
d) None of the mentioned
.

Answer: c
Explanation: Selected machining conditions should remain unchanged, because, it will have a direct impact on accuracy and surface finish.

92. Surface roughness depends on current density, which is affected by which of the following?
a) Tool feed rate
b) Gap voltage
c) Work piece material
d) All of the mentioned
.

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.

93. 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
.

Answer: b
Explanation: Accuracy is associated with smaller surface roughness and greater machining productivity.

94. Non stationary behaviour of ECM is due to, which of the factors below?
a) Gas generation
b) Heating
c) Passivation
d) All of the mentioned
.

Answer: d
Explanation: Non stationary behaviour of ECM is due to the inter electrode gap conditions such as gas generation, passivation, heating and other electrode reactions.

95. For large components, actual machining time constitutes to how much percentage of the total machining time?
a) Very low
b) Low
c) Medium
d) High
.

Answer: d
Explanation: Actual machining time of large components constitutes to a high percentage of total machining time.
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96. What happens to the product cycle time, if the machining performance is improved?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned
.

Answer: b
Explanation: As the machining performance is improved, the time take for a product to complete its production cycle, decreases.

97. The cost of additional control hardware remain a _________ fraction of total machining cost.
a) Small
b) Large
c) Equal
d) None of the mentioned
.

Answer: a
Explanation: Cost of additional control hardware is very less, which constitutes to a small fraction in total machining cost.

98. 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.

99. 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.

100. Which type of damage is caused by deterioration which is caused by spark?
a) Reparable
b) Irreparable
c) All of the mentioned
d) None of the mentioned
.

Answer: b
Explanation: Deterioration by sparking may cause irreparable damage to the work pieces.

101. Which of the following use ECM for different applications?
a) Gas turbines
b) Jet engines
c) Bio medical implants
d) All of the mentioned
.

Answer: d
Explanation: ECM has its applications in industries such as gas turbines, jet engines, automobiles, medical etc.

102. Which of the following processes can be done using ECM?
a) Die sinking
b) Profiling and contouring
c) Drilling and trepanning
d) All of the mentioned
.

Answer: d
Explanation: ECM can be used for die sinking, trepanning, drilling, contouring, grinding and profiling.

103. Which of the following material cannot be machined using ECM?
a) High strength alloys
b) Hardened steels
c) Nonconductive materials
d) All of the mentioned
.

Answer: c
Explanation: ECM can be used for machining high strength alloys and hardened steels which led to many cost-saving applications.

104. ECM is used to _________ the sharp edges produced after rough cuts.
a) Enhance
b) Dull
c) Improve
d) None of the mentioned
.

Answer: b
Explanation: Using deburring process through ECM, sharp edges are dulled, which are produced after rough cuts.

105. 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
d) All of the mentioned
.

Answer: b
Explanation: ECM is usually characterized as low accuracy machining because of its wider machining gap.

106. In micro ECM, which of the following is used as micro tool?
a) Electrolyte jet
b) Electrodes
c) Power supply
d) All of the mentioned
.

Answer: a
Explanation: Electrolyte jet in micro ECM acts as the micro tool for machining.

107. Micro ECM is used to machine which type of parts?
a) Large parts
b) Micro parts
c) Normal sized parts
d) All of the mentioned
.

Answer: b
Explanation: Micro ECM is used to machine micro parts which can be from micro scale to mesoscale in size.

108. Which of the following produces small indents and cavities using micro ECM?
a) Moving the work piece
b) Switching the pulse current
c) Moving the work piece & Switching the pulse current
d) None of the mentioned
.

Answer: c
Explanation: Indentation and cavitation can be done using micro ECM by moving the work piece or switching the pulse current.

109. What fraction of tool will always be in contact with the work piece?
a) Half
b) Full
c) No contact
d) Quarter
.

Answer: c
Explanation: Tool does not have any contact with the work piece in Electro chemical machining.

110. How much amount of wear is present in the tool used in Electrochemical machining?
a) No wear
b) Low
c) Medium
d) High
.

Answer: a
Explanation: The tool wear is absent in the tool used in ECM, since tool has no contact with the work piece.

111. Compared to other processes, machining is done at __________ voltages for high rates of material removal.
a) Low
b) Medium
c) High
d) very low
.

Answer: c
Explanation: In ECM, machining is done at low voltages, when compared to other processes.

112. Very small dimensions, up to which value can be controlled using ECM?
a) 0.01 mm
b) 0.05 mm
c) 0.07 mm
d) 0.12 mm
.

Answer: b
Explanation: Due to less electrode gap very small dimensions up to 0.05 mm can be controlled.

113. Complicated profiles can be machined in how many operations in Electrochemical machining?
a) Single
b) Double
c) Triple
d) Multiple
.

Answer: a
Explanation: One of the main advantage of ECM is, complicated profiles can be machined in a single operation itself.
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114. 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.

115. Which of the following materials can be machined using ECM?
a) Hard nonconductive materials
b) Hard conductive materials
c) All nonconductive materials
d) None of the mentioned
.

Answer: b
Explanation: Hard conductive materials can be machined and nonconductive materials cannot be machined using ECM.

116. What are the requirements of labour for machining purpose in Electrochemical machining?
a) Low
b) Medium
c) High
d) Very high
.

Answer: a
Explanation: In electrochemical machining, labour requirements are low compared to conventional or traditional machining practices.

117. How much amount of energy is consumed in Electro chemical machining?
a) Very small
b) Small
c) Medium
d) Large
.

Answer: d
Explanation: Very huge amount of energy is required for ECM, which is nearly 100 times required for turning or drilling of steel.

118. How are material removal rates of ECM, when compared to that of conventional methods?
a) Slower
b) Faster
c) Same
d) None of the mentioned
.

Answer: a
Explanation: In ECM, rates of material removal are slow compared to conventional methods.

119. State whether the following statement is true or false regarding the limitations of ECM.
“In ECM, cleaning and oiling of work piece need not be done after machining.”
a) True
b) False
.

Answer: b
Explanation: Work piece needs to be cleaned and oiled just after the machining is done.

120. Which of the following are the limitations of electro chemical machining?
a) Removal of hydrogen
b) Handling the electrolyte
c) Energy consumption
d) All of the mentioned
.

Answer: d
Explanation: Removal of hydrogen, handling and containing the electrolyte and energy consumption are some of the limitations of ECM.

121. 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.

122. Electro chemical machining process cannot produce which of the following mentioned below?
a) Drilled holes
b) Deburred edges
c) Sharp edges
d) All of the mentioned
.

Answer: c
Explanation: Electro chemical machining cannot produce sharp internal or external edges.

123. Pumping of electrolyte through the narrow gaps causes, which type of forces on tool and work piece?
a) Large
b) Small
c) Negligible
d) No force
.

Answer: a
Explanation: Electrolyte pumping through the narrow gaps gives rise to a large amount of forces on tool and work pieces.

124. If electro chemical machining is applied under appropriate conditions, how much amount of health dangers can occur?
a) Small amount
b) Limited amount
c) Large amount
d) Very large amount
.

Answer: b
Explanation: Occupational health dangers are limited if ECM is done at appropriate conditions.

125. Which of the following are some of the bad impacts on environment while using ECM?
a) Electrolyte splashing
b) Toxic gases release
c) Precipitation of solid matters
d) All of the mentioned
.

Answer: d
Explanation: Electrolyte splashing, precipitation of solid matter, and toxic gas release is very harmful to the environment.

126. Which of the following parts of the body can be contaminated while using ECM?
a) Skin
b) Eyes
c) Skin & Eyes
d) None of the mentioned
.

Answer: c
Explanation: Contamination of skin and eyes may occur due to electrolyte splashing and toxic gas release.

127. During deburring and die sinking which of the following electrolyte gives high surface quality and accuracy?
a) NaNO3
b) HNO3
c) NaCl
d) All of the mentioned
.

Answer: a
Explanation: By using NaNO3, deburring and die sinking can be done with more accuracy and high qualities are obtained.

128. Dissolution of metal containing chrome results in which of the toxic compounds?
a) Toxic chromate
b) Ammonia
c) Toxic chromate & Ammonia
d) None of the mentioned
.

Answer: c
Explanation: Dissolution of metal containing chromate results nitrate reduction at cathode tool, which in turn produces toxic chromate and ammonia.

129. Slurries mixing with toxic compounds produce, which of the following?
a) Solid precipitates
b) Liquid solutions
c) All of the mentioned
d) None of the mentioned
.

Answer: a
Explanation: Slurries which mix with toxic compounds such as chromate and ammonia precipitates solid matter in the electrolyte solution.

130. What should be done to the electrolyte with solid matter?
a) Can be reused
b) Disposed off
c) No disposing is necessary
d) All of the mentioned
.

Answer: b
Explanation: The electrolyte which contain the solid precipitates needs to be disposed immediately, in order to avoid any damage to the environment.

131. State whether the following statement is true or false regarding the environmental impacts of ECM.
“In ECM, accumulation of toxic compounds is due to nitrate reduction at tool cathode.”
a) True
b) False
.

Answer: a
Explanation: When chromate containing metals dissolute, nitrate accumulate at cathode tool, which results in toxic chromate and ammonia compounds.

132. What is the full form of ECDR in advanced machining processes?
a) Electrochemical Dissolution
b) Electrochemical Drilling
c) Electrochemical Degradation
d) Electrochemical Devastation
.

Answer: b
Explanation: In advanced machining processes, full form of ECDR is Electrochemical Drilling.

133. What are the values of diameters produced using Electrochemical drilling process?
a) 0.01 to 0.2 mm
b) 1 to 20 mm
c) 30 to 50 mm
d) 60 to 100 mm
.

Answer: b
Explanation: Value of diameter produced using Electrochemical drilling, ranges between 1 to 20 mm.

134. What are the feed rates used in Electrochemical drilling?
a) 0.1 to 0.6 mm/min
b) 0.6 to 1 mm/min
c) 1 to 5 mm/min
d) 6 to 15 mm/min
.

Answer: c
Explanation: Value of feed rates used in Electrochemical drilling, range between 1 to 5 mm/min.

135. Of the following, which type of electrodes is used as tool in ECDR?
a) Tubular electrodes
b) Flat electrodes
c) Cylindrical electrodes
d) All of the mentioned
.

Answer: a
Explanation: In ECDR, tubular electrodes are used as cathodic tools for making holes in the materials.

136. The electrolyte is pumped the ________ of tool and exits through _________ of tool.
a) Centre, side
b) Side, centre
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: Usually, electrolyte is pumped from centre and exits from side machining gap and vice-versa can also be done in back pressure process.

137. Material is removed using which part of the electrode in ECDR?
a) Only front
b) Only side
c) Front and side
d) None of the mentioned
.

Answer: c
Explanation: Material is removed at the frontal gaps and also dissolution takes place at the side machining gaps of the cathodic tool and work piece.

138. Overcut produced in ECRD is difference between which of the following parameters?
a) Diameter of tool, diameter of hole
b) Diameter of hole, diameter of tool
c) Depth of tool, diameter of tool
d) Diameter of tool, depth of tool
.

Answer: b
Explanation: Overcut is the difference between the diameter of hole produced in work piece and the diameter of tool.

139. For high machining accuracy and smaller diametrical oversize, which type of feed rates are required?
a) Very low
b) Low
c) Medium
d) High
.

Answer: d
Explanation: High feed rates are recommended for smaller diametrical oversize and more accuracy.

140. What happens to the overcut size, if we use the electrolyte flow mode under backward pressure?
a) Decreases
b) Increases
c) Increase and then decrease
d) None of the mentioned
.

Answer: a
Explanation: If we use backward pressure for electrolyte flow, the overcut size decreases.

141. What are the values of pressure, used in backward pressure mode of electrolyte flow?
a) 0.01 to 0.12 MPa
b) 0.15 to 0.46 MPa
c) 0.6 to 2 MPa
d) 5 to 12 MPa
.

Answer: c
Explanation: To reduce overcut size, reverse flow of electrolyte can be used under backward pressure mode, whose value ranges between 0.6 to 2 MPa.

142. What happens to the electrolyte conductivity if the gap increases, in ECDR?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned
.

Answer: a
Explanation: In ECDR, as the gap increases, the electrical conductivity increases and the dissolution of material increases.

143. Electrolyte back pressure _________ the flow lines on work piece machined using ECDR.
a) Enhances
b) Eliminates
c) Maintains
d) Increases
.

Answer: b
Explanation: Electrolyte back pressure eliminates the flow lines on the machined surfaces which is a major advantages of ECDR.

144. What happens to the roundness error if we use the rotation of ECDR tool?
a) Increases
b) Remains same
c) Decreases
d) Enhances
.

Answer: c
Explanation: Roundness error decreases, if the tool is rotated in ECDR, since it ensures the homogenous flow of electrolyte in the machining gaps.

145. If sparking occurs due to very less gap between work surfaces, which parts gets damaged?
a) Tool
b) Work piece
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: Sparking, which occur due to very less gap between tool and work piece, which damages both the parts in ECDR.

146. Current efficiencies <100 percent may be related to, which of the following incidents?
a) Gas evolution
b) Passive oxide film formation
c) Less dissolution
d) All of the mentioned
.

Answer: d
Explanation: Current efficiencies less than 100 percent may be related to gas evolution, passive oxide formation, which in turn lead to less dissolution.

147. What is the full form of STEM in advanced machining processes?
a) Small Tool Electrode Machining
b) Small Tube Electrode Manufacturing
c) Shaped Tube Electrolytic Machining
d) Shaped Tube Electrode Machining
.

Answer: c
Explanation: Full form of STEM in advanced machining processes is Shaped tube electrolytic machining.

148. Material is removed on which basis, in Shaped tube electrolytic machining?
a) Dissolution
b) Vaporization
c) Abrasion
d) Erosion
.

Answer: a
Explanation: In STEM, dissolution takes place when a potential difference is applied between the anodic work piece and cathodic tool.

149. Which of the following can be used as electrolytes in STEM process?
a) Sulphuric acid
b) Nitric acid
c) Hydrochloric acids
d) All of the mentioned
.

Answer: d
Explanation: Electrolytes used in STEM are sulphuric acid, nitric acid and hydrochloric acids.

150. What is the percentage of electrolyte dissolved in water?
a) 1 – 5%
b) 10 – 25%
c) 40 – 70%
d) 75 – 90%
.

Answer: b
Explanation: Concentration of electrolyte, used in STEM, is 10 – 25% weight in water.

151. What may be the temperature of sulphuric acid used in the STEM process?
a) 10 oC
b) 21 oC
c) 38 oC
d) 50 oC
.

Answer: c
Explanation: The temperature of sulphuric acids used in the STEM process may be around 38 oC.
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152. What may be the temperatures of acids used, other than sulphuric acid, in STEM?
a) 10 oC
b) 21 oC
c) 38 oC
d) 50 oC
.

Answer: b
Explanation: Temperature of acids used in STEM, other than sulphuric acid, is about 21 oC.

153. What are the values of pressures used for electrolyte in STEM?
a) 10 – 100 kPa
b) 150 – 250 kPa
c) 275 – 500 kPa
d) 600 – 750 kPa
.

Answer: c
Explanation: Values of pressure used in the STEM process, range between 275 – 500 kPa.

154. What are the voltage values used in the STEM process?
a) 1 – 4 V
b) 8 – 14 V
c) 16 – 24 V
d) 28 – 34 V
.

Answer: b
Explanation: In STEM, voltage values used for the process to carry on, range between 8 – 14 V.

155. Compared to the forward voltages, how are the reverse voltages?
a) 0.01 – 0.1 times
b) 0.1 – 1 times
c) 1 – 10 times
d) 10 – 100 times
.

Answer: b
Explanation: Reverse voltages used in STEM are 0.1 – 1 times the forward voltages, used in STEM.

156. Which of the following values, does the feed rate range between?
a) 0.01 – 0.1 mm/min
b) 0.25 – 0.5 mm/min
c) 0.75 – 3 mm/min
d) 5 – 7.5 mm/min
.

Answer: c
Explanation: Feed rates used in STEM, range between 0.75 – 3 mm/min.

157. What may the hole sizes, that can be machined using STEM process?
a) 0.02 – 0.3 mm
b) 0.5 – 6 mm
c) 8 – 20 mm
d) 50 – 76 mm
.

Answer: b
Explanation: The hole sizes that can be machined using STEM process, range between 0.5 – 6 mm.

158. What are the tolerance values for a 1.5 mm diameter hole, which is machined using STEM?
a) ± 0.025 mm
b) ± 0.050 mm
c) ± 0.075 mm
d) ± 0.100 mm
.

Answer: c
Explanation: Diametrical tolerance value increases with the increase in hole diameter, which varies as – ± 0.050 mm for 0.6 mm diameter hole, ± 0.075 mm for 1.5 mm diameter hole and ± 0.100 mm for 6 mm hole diameter.

159. Which of the following parts can be machined using STEM process?
a) Turbine blade cooling nozzles
b) Fuel nozzles
c) Starting holes for wire-EDM
d) All of the mentioned
.

Answer: d
Explanation: STEM has its applications in jet engines and gas turbine parts such as cooling nozzles for turbine blades, fuel nozzles and any holes where EDM recast is undesirable.

160. Which of the following are the advantages of STEM?
a) Depth to diameter ratio of 300
b) Non parallel holes can be drilled
c) No recast layer
d) All of the mentioned
.

Answer: d
Explanation: Main advantages of STEM are depth to diameter ratio of 300, non-parallel holes can be drilled, no recast layer are produced, shaped and curved holes can be produced.

161. What are the limitations of STEM process?
a) Used for corrosion resistant materials
b) Hazardous waste is generated
c) Complex machining and tooling systems
d) All of the mentioned
.

Answer: d
Explanation: Some of the limitations of STEM are only used for corrosion resistant materials, hazardous wastes are generated, special work place environment are required, complex machining and tooling systems are required.

162. In advanced machining processes, what is the full form of ES drilling?
a) Electro stream
b) Electrical shaped
c) Electron shaped
d) Electric shock
.

Answer: a
Explanation: In advanced machining processes, full form of ES drilling is Electrostream drilling.

163. This Electrostream drilling is used when we cannot drill which of the following type of holes?
a) Too deep holes by EDM
b) Small holes by STEM
c) All of the mentioned
d) None of the mentioned
.

Answer: c
Explanation: ES drilling is used to drill finer holes which are too deep to be produced by EDM and too small to be drilled by STEM.

164. What is the value of diameter of glass nozzle used in Electrostream drilling?
a) 0.01 – 0.02 mm
b) 0.025 – 0.5 mm
c) 0.5 – 0.75 mm
d) 0.75 – 1.25 mm
.

Answer: b
Explanation: Electrostream drilling uses a gas nozzle, whose diameter ranges between 0.025 – 0.5 mm.

165. Compared to the required diameter of the hole, how is the nozzle diameter?
a) Smaller
b) Larger
c) Same as required
d) All of the mentioned
.

Answer: a
Explanation: The diameter of nozzle used is smaller than the hole size required to be drilled in work piece.

166. Which of the following acts as the cathodic tool in ES drilling?
a) Titanium base
b) Platinum wire
c) Glass nozzle
d) Work piece
.

Answer: b
Explanation: Unlike the case of STEM process, which uses coated Ti tube as cathode, ES drilling used platinum wire as cathode electrode.
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167. What is the concentration of electrolytes that are commonly used in ES drilling?
a) 1 to 10wt %
b) 12 to 20wt %
c) 23 to 30wt %
d) 34 to 50wt %
.

Answer: b
Explanation: Commonly used electrolytes have a concentration between 12 to 20wt %.

168. State whether the following statement is true or false regarding ES drilling.
“In ES drilling, hydrochloric acid is used for machining aluminium and its alloys.”
a) True
b) False
.

Answer: a
Explanation: Hydrochloric acids are used for machining Al and its alloys and sulphuric acid is recommended for other metals.

169. Which of the following are the metals, which can be machined using sulphuric acid?
a) Carbon steels
b) Haste alloy
c) Inconel
d) All of the mentioned
.

Answer: d
Explanation: Haste alloy, Rene alloy, Inconel, carbon and stainless steels are the materials machined using sulphuric acid.

170. What are the values of electrolyte pressure recommended for ES drilling?
a) 50 – 100 kPa
b) 100 – 250 kPa
c) 275 – 400 kPa
d) 500 – 750 kPa
.

Answer: c
Explanation: Electrolyte pressure values must range between 275 – 400 kPa for ES drilling to take place.

171. Which of the following parameters must be carefully monitored for satisfactory machining?
a) Acid temperature
b) Pressure
c) Concentration
d) All of the mentioned
.

Answer: d
Explanation: Acid temperature, pressure, concentration and feed rate are to be carefully monitored for satisfactory machining.

172. What are the values of voltages used in ES drilling process?
a) 10 to 40 V
b) 40 to 70 V
c) 70 to 150 V
d) 150 to 300 V
.

Answer: c
Explanation: Voltage values used in ES drilling, range between 70 to 150 V.

173. What are the values of feed rates used in ES drilling process?
a) 0.01 to 0.5 mm/min
b) 0.75 to 2.5 mm/min
c) 3 to 4.5 mm/min
d) 5 to 7.5 mm/min
.

Answer: b
Explanation: Feed rate values used in ES drilling, range between 0.75 to 2.5 mm/min.

174. Higher material removal rates are associated with _________ feed rates and _________ tool diameters.
a) Larger, smaller
b) Smaller, larger
c) Smaller, smaller
d) Larger, larger
.

Answer: d
Explanation: Rates of material removal are high, when feed rates are high and larger tool diameters.

175. What are the normal hole depth tolerance values in ES drilling?
a) ± 0.03 mm
b) ± 0.05 mm
c) ± 0.07 mm
d) ± 0.09 mm
.

Answer: b
Explanation: The normal hole depth tolerances obtained in ES drilling, range between ± 0.05 mm.

176. How many holes can be drilled simultaneously using ES drilling process?
a) One hole
b) Two holes
c) Three holes
d) Multiple holes
.

Answer: d
Explanation: Depending upon the size of diameters, multiple holes can be drilled using ES drilling.

177. In advanced machining processes, what is the full form of ECJD?
a) Electrochemical Jet Dimensioning
b) Electrochemical Jet Drilling
c) Electrical Jet Drilling
d) Electrical Jet Dimensioning
.

Answer: b
Explanation: In advanced machining processes, full form of ECJD is Electrochemical Jet Drilling.

178. What is the value of diameter-to-depth ratio obtained using ECJD process?
a) 1:10
b) 2:25
c) 1:12
d) 1:100
.

Answer: c
Explanation: Electrochemical jet drilling is the process used for producing fine holes, having diameter to depth ratio of 1:12.

179. Compared to the diameter to depth ratio of ES drilling, how is ECJD’s ratio?
a) Lower
b) Higher
c) Same as ES
d) None of the mentioned
.

Answer: a
Explanation: ES drilling has a diameter to depth ratio of 1:100, while ECJD has a ratio of 1:12.

180. How is the material removed in Electrochemical jet drilling process?
a) Using Platinum wire
b) Using Ti coated electrode
c) By spraying electrolyte
d) Using glass nozzle
.

Answer: c
Explanation: Material is removed by spraying electrolyte through the cathode, in Electrochemical jet drilling.

181. What is the material removal mechanism used in Electrochemical jet drilling?
a) Abrasion
b) Dissolution
c) Vaporization
d) Erosion
.

Answer: b
Explanation: Electrochemical dissolution is the means of material removal in Electrochemical jet drilling.

182. What are the values of voltages used in Electrochemical jet drilling process?
a) 100 to 200 V
b) 200 to 400 V
c) 400 to 800 V
d) 800 to 1600 V
.

Answer: c
Explanation: The optimum range of voltages used in Electrochemical jet drilling are between 400 to 800 V.

183. The lower limit of the hole size in ECJD, is determined by which of the following factors?
a) Smallest hole
b) Pressure required
c) Amount of overcut
d) All of the mentioned
.

Answer: d
Explanation: The lower limit of hole size depend on smallest hole that can be drilled in cathodic nozzle, pressure required for pumping electrolyte and the overcut amount.

184. State whether the following statement is true or false regarding ECJD.
“In ECJD, diameter of hole produced, depend up on the throwing power of electrolyte.”
a) True
b) False
.

Answer: a
Explanation: Diameter of the hole produced, depend up on the throwing power of electrolyte.

185. Compared to the diameter of the electrolyte jet, how are the produced hole diameters?
a) 2 times
b) 3 times
c) 4 times
d) 5 times
.

Answer: c
Explanation: In ECJD, the holes produced are nearly 4 times that of the electrolyte jet diameter used in the process.

186. What is the value of the ratio of hole diameter to capillary diameter in ECJD?
a) 2
b) 4
c) 6
d) 8
.

Answer: a
Explanation: Generally, ratio of hole diameter to capillary diameter in ECJD is 2.

187. What are the values of tapers produced in Electrochemical jet drilling process?
a) 1 to 2 included angles
b) 5 to 10 included angles
c) 10 to 15 included angles
d) 20 to 30 included angles
.

Answer: b
Explanation: In Electrochemical jet drilling tapers produced are about 5 to 10 included angles.

188. State whether the following statement is true or false regarding ECJD?
“In ECJD, there is no need of room for exit of electrolyte.”
a) True
b) False
.

Answer: b
Explanation: In ECJD, enough room is required for the exit of electrolyte, preferably in the form of spray.

189. How much part of tool needs to be in contact with work piece for removal of material?
a) Quarter
b) Half
c) Full
d) No contact
.

Answer: d
Explanation: As this is an electrochemical dissolution process, electrodes should not be in contact in order to avoid sparking.

190. In advanced machining processes, full form of ECDB is _________
a) Electrochemical Drill buffing
b) Electrochemical Dimension Breaking
c) Electrochemical Deburring
d) Electrochemical Dimensioning
.

Answer: c
Explanation: In advanced machining processes, full form of ECDB is Electrochemical Deburring.

191. Which of the following processes can be used for deburring?
a) Water blasting
b) Abrasive flow machining
c) Electrochemical deburring
d) All of the mentioned
.

Answer: d
Explanation: Different methods used for deburring include vibratory and barrel finishing, tumbling, water blasting, Abrasive flow machining, Electrochemical deburring and many more.

192. In the following electrodes, on which one the process of deburring takes place?
a) Cathode
b) Anode
c) Cathode & Anode
d) None of the mentioned
.

Answer: c
Explanation: Anode is the electrode, on which, the process of deburring is done.

193. Burrs are removed at which amount of current densities below?
a) Very low
b) Low
c) High
d) Medium
.

Answer: c
Explanation: High current densities are required to remove the burrs from the work pieces.

194. After deburring is done, which of the following is formed?
a) Flat surfaces
b) Controlled radius
c) Sharp edges
d) All of the mentioned
.

Answer: b
Explanation: Dimensions of the part are changes by the removal of burrs leaving a controlled radius.
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195. To which components mentioned below, ECDM can be applied?
a) Spline shafts
b) Milled components
c) Drilled holes
d) All of the mentioned
.

Answer: d
Explanation: ECDB can be applied to gears, spline shafts, milled components, drilled holes, and punched blanks.

196. What are the values of deburring speeds used in ECDB process?
a) 100 to 200 mm/min
b) 200 to 400 mm/min
c) 400 to 500 mm/min
d) 500 to 700 mm/min
.

Answer: c
Explanation: Values of speeds of deburring, range between 400 to 500 mm/min.

197. What are the normal cycle times for deburring process using ECDB?
a) 10 to 20 s
b) 30 to 45 s
c) 50 to 70 s
d) 80 to 100 s
.

Answer: b
Explanation: The normal cycle times are between 30 to 45 s after which, spindle is retracted and part is removed.

198. What is the value of burr height that can be removed using ECDB process?
a) 0.1 mm
b) 0.3 mm
c) 0.5 mm
d) 0.7 mm
.

Answer: c
Explanation: Burr height of around 0.5 mm can be removed using ECDB process.

199. Burr is removed to a radius of _________ in ECDB process.
a) 0.01 to 0.04 mm
b) 0.05 to 0.20 mm
c) 0.25 to 0.40 mm
d) 0.50 to 0.75 mm
.

Answer: b
Explanation: Burr of height 0.5 mm to a radius of 0.05 to 0.2 mm can be removed using ECDB.

200. What is the value of surface roughness obtained in Electrochemical deburring process?
a) 0.1 to 1 µm
b) 1 to 2 µm
c) 2 to 4 µm
d) 5 to 8 µm
.

Answer: c
Explanation: Surface roughness obtained in ECDB process is about 2 to 4 µm

201. What is the value of pressure of electrolyte used in ECDB process?
a) 0.1 to 0.2 MPa
b) 0.3 to 0.5 MPa
c) 0.7 to 0.9 MPa
d) 1.1 to 1.5 MPa
.

Answer: b
Explanation: Pressure of electrolyte used in ECDB is maintained between 0.3 to 0.5 MPa.

202. What is the value of applied voltage used in ECDB process?
a) 1 to 5 V
b) 5 to 11 V
c) 12 to 24 V
d) 25 to 50 V
.

Answer: c
Explanation: Value of voltage used in ECDB process ranges from 12 to 24 V.

203. What are the values of current densities used in ECDB process?
a) 1 – 5 A/cm2
b) 5 – 10 A/cm2
c) 10 – 15 A/cm2
d) 15 – 20 A/cm2
.

Answer: b
Explanation: Current densities used in ECDB process range between 5 – 10 A/cm2.

204. Which of the following electrolyte can be used for deburring process in ECDB?
a) NaNO2
b) NaNO3
c) NaCl
d) All of the mentioned
.

Answer: d
Explanation: Sodium nitrite, sodium nitrate and sodium chloride are the electrolytes used in ECDB process.

205. What are the values, of inter electrode gaps so that machining occurs easily?
a) 0.01 to 0.1 mm
b) 0.1 to 0.3 mm
c) 0.3 to 0.5 mm
d) 0.5 to 0.7 mm
.

Answer: c
Explanation: The inter electrode gap maintained in ECDB process, range between 0.30 – 0.50 mm.

206. In order to produce a proper radius, by how much should the tool tip overlap the machined area?
a) 0.5 to 1 mm
b) 1 to 1.5 mm
c) 1.5 to 2 mm
d) 2 to 2.5 mm
.

Answer: b
Explanation: In ECDB, the tool tip should overlap the machined area by 1.5 to 2 mm in order to produce a proper radius.

207. Which of the following materials can be machined using ECDB process?
a) Carbon steels
b) Copper alloys
c) Aluminium alloys
d) All of the mentioned
.

Answer: d
Explanation: All the materials mentioned above, can be machined using ECDB process.

208. In ECDB process, rotating and feeding the tool electrode __________ the deburring process.
a) Enhances
b) Degrades
c) Damages
d) All of the mentioned
.

Answer: a
Explanation: Rotating and feeding the tool in ECDB process, enhances the process of deburring.

209. Electrochemical deburring ensures which of the following factors after removal of burrs?
a) Required accuracy
b) Proper radius
c) Clean edge
d) All of the mentioned
.

Answer: d
Explanation: ECDB ensures the removal of burrs art required accuracy, uniformity, proper radius and clean edges.

210. Which of the following are the advantages of using ECDB process?
a) Increased product quality
b) Reduced labour cost
c) Increased reliability
d) All of the mentioned
.

Answer: d
Explanation: Increased product quality and reliability, reduced labour costs, elimination of costly hand deburring etc.., are some of the advantages of ECDB.

211. State whether the following statement is true or false regarding the advantages of ECDB.
“In ECDB, automation does not contribute to productivity.”
a) True
b) False
.

Answer: b
Explanation: Electrochemical deburring can be automated for higher productivity.

Hybrid Electrochemical Processes

1. What is the full form of ECG in the advanced machining processes?
a) Electro cardio graph
b) Electro chemical grinding
c) Electro chemical grooving
d) Electric cathode grinding

Answer & Explanations

Answer: b
Explanation: The full form of ECG in the advanced machining processes is Electro chemical grinding.

2. The grinding wheel used in the ECG process is of which charge given below?
a) Positive charge
b) Negative charge
c) Neutral charge
d) All of the mentioned

Answer & Explanations

Answer: c
Explanation: The abrasive grinding wheel used in the Electro chemical grinding process is negatively charged.

3. Which of the following mentioned below are utilized in the ECG process?
a) Electrolytic solution
b) Abrasive grinding wheel
c) Work piece
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: Electro chemical grinding utilizes the abrasive grinding wheel, the electrolytic solution and the work piece.

4. Electro chemical grinding is ___________ Electro chemical machining.
a) Superior to
b) Inferior to
c) Similar to
d) None of the mentioned

Answer & Explanations

Answer: c
Explanation: The process of Electro chemical grinding is similar to that of ECM except the cathode is a constructed grinding wheel.

5. What is the value of inter electrode gap maintained in ECG process?
a) <0.015 mm
b) <0.025 mm
c) <0.035 mm
d) <0.045 mm

Answer & Explanations

Answer: b
Explanation: The value of the inter electrode gap maintained in Electro chemical grinding is 0.025 mm or less.

6. What is the value of the grit number of the abrasives used in ECG?
a) 1 – 20
b) 20 – 60
c) 60 – 320
d) 350 – 640

Answer & Explanations

Answer: c
Explanation: The value of the grit number of abrasive particles used in the ECG process are about 60 – 320.

7. Which of the following electrolytes are used for machining purpose in ECG?
a) Sodium nitrate
b) Hydro chloric acid
c) Nitric acid
d) Potassium permanganate

Answer & Explanations

Answer: a
Explanation: Generally sodium nitrate is the electrolyte that is used for machining purpose in Electro chemical grinding.

8. What are the values of surface speeds at which the wheel rotates?
a) 5 to 15 m/s
b) 10 to 20 m/s
c) 20 to 35 m/s
d) 40 to 60 m/s

Answer & Explanations

Answer: c
Explanation: The speeds used in ECG will range from 20 to 35 m/sec.

9. What are the values of current used in ECG?
a) 1 to 50 A
b) 50 to 300 A
c) 300 to 600 A
d) 600 to 1000 A

Answer & Explanations

Answer: c
Explanation: The values of current in Electro chemical grinding range from 50 to 300 A.

10. State whether the following statement is true or false regarding the material removal in ECG.
“In ECG, material removal is not continuous using abrasive.”
a) True
b) False

Answer & Explanations

Answer: b
Explanation: Abrasive particles continuously remove the material products from the working area in Electro chemical grinding.

11. What is the value of gap voltage maintained in ECG process?
a) 1 to 10 V
b) 4 to 40 V
c) 40 to 400 V
d) 500 to 5000 V

Answer & Explanations

Answer: b
Explanation: The value of the gap voltage in ECG process is 4 to 40 V.

12. What are the values of current densities used in the ECG process?
a) 1 to 60 A/cm2
b) 60 to 120 A/cm2
c) 120 to 240 A/cm2
d) 240 to 480 A/cm2

Answer & Explanations

Answer: c
Explanation: The values of current densities range from 120 to 240 A/cm2.

13. Current density depends on which of the following factors?
a) Machined material
b) Gap width
c) Applied voltage
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: The current density values in Electro chemical grinding depend on machined material, gap width and the applied voltage.

14. What is the main mechanism of material removal in Electro chemical grinding?
a) Mechanical erosion of material
b) Electro chemical dissolution
c) Melting and vaporization
d) Electron removal from material

Answer & Explanations

Answer: b
Explanation: Electro chemical grinding process removes the material mainly by electro chemical dissolution.

15. The grinding wheel is _________ and the work piece is ________ in ECG process.
a) Cathode, anode
b) Anode, cathode
c) Cathode, cathode
d) Anode, anode

Answer & Explanations

Answer: a
Explanation: The grinding wheel is cathode and the work piece is anode in the Electro chemical grinding process.
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16. Mechanical abrasion counts to how much amount of the material removal in ECG?
a) 1 to 5%
b) 5 to 10%
c) 10 to 15%
d) 15 to 20%

Answer & Explanations

Answer: b
Explanation: Material removal through abrasion counts to 5 to 10% of the total material removed.

17. Removal rates of ECG process are how may time to that of the conventional machining processes?
a) 2 times
b) 3 times
c) 4 times
d) 5 times

Answer & Explanations

Answer: c
Explanation: The MRR of ECG process are nearly 4 times that of the conventional machining processes.

18. How much amount of burr is produce in Electro chemical grinding process?
a) Less amount
b) Moderate amount
c) High amount
d) No burrs are produced

Answer & Explanations

Answer: d
Explanation: The Electro chemical grinding process is a burr free process which produce parts that are unstressed.

19. What are the volumetric removal rates that are obtained in ECG process?
a) 400 mm3/min
b) 800 mm3/min
c) 1600 mm3/min
d) 3200 mm3/min

Answer & Explanations

Answer: c
Explanation: The volumetric removal rates that are obtained in Electro chemical grinding process will be around 1600 mm3/min.

20. ECG is a hybrid machining process of which material removal mechanisms below?
a) Mechanical abrasion
b) Electro chemical dissolution
c) Mechanical abrasion & Electro chemical dissolution
d) None of the mentioned

Answer & Explanations

Answer: c
Explanation: ECG is a hybrid machining process which uses MA and ECD for material removal.

21. Action of abrasive grains depend on which of the following factors?
a) Electric filed
b) Transport of electrolyte
c) Hydrodynamic effects
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: Action pf abrasive grains in the gap depends on the electric field, transport of electrolyte and the hydrodynamic effects.

22. What are the tolerance value that are obtained by using ECG process?
a) ± 0.01 mm
b) ± 0.03 mm
c) ± 0.05 mm
d) ± 0.07 mm

Answer & Explanations

Answer: b
Explanation: The tolerance values that are obtained by using Electro chemical grinding are about ± 0.03 mm.

23. Under special circumstances what are the tolerances obtained?
a) ± 0.02 mm
b) ± 0.04 mm
c) ± 0.06 mm
d) ± 0.08 mm

Answer & Explanations

Answer: d
Explanation: The tolerance values of about ± 0.08 mm are obtained under special circumstances in Electro chemical grinding.

24. What are the production tolerances obtained in ECG process?
a) ± 0.005 mm
b) ± 0.015 mm
c) ± 0.025 mm
d) ± 0.035 mm

Answer & Explanations

Answer: c
Explanation: The production tolerances obtained by machining using Electro chemical grinding process is about ± 0.025 mm.

25. The tolerance values in ECG depend on which of the following factors?
a) Electrolyte flow
b) Feed rate
c) Metallurgy of material
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: The tolerance values depend on the electrolyte flow, feed rate and the metallurgy of work piece.

26. What are the values of accuracies obtained in ECG process?
a) ± 0.025 mm
b) ± 0.125 mm
c) ± 0.225 mm
d) ± 0.325 mm

Answer & Explanations

Answer: b
Explanation: The accuracy values obtained by using Electro chemical grinding process is about ± 0.125 mm.

27. Which type of voltages are recommended for closer tolerances in ECG?
a) Low
b) Moderate
c) High
d) Very high

Answer & Explanations

Answer: a
Explanation: Lower voltages are recommended for closer tolerances, reduced overcut, sharp edges and bright surface finish in the process of Electro chemical grinding.

28. What are the values of radii of corners obtained in ECG?
a) 0.15 to 0.225 mm
b) 0.25 to 0.375 mm
c) 0.45 to 0.525 mm
d) 0.55 to 0.675 mm

Answer & Explanations

Answer: b
Explanation: The values of radii of corner range from 0.25 to 0.375 mm.

29. Surface finish in ECG depend on which of the following factors?
a) Metal machined
b) Abrasive size
c) Wheel speed
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: Surface finish in ECG process depend on metal being machined, abrasive grit size, wheel speed and feed rate.

30. What are the values of radii of corners obtained in ECG?
a) 0.1 to 0.2 µm
b) 0.2 to 0.3 µm
c) 0.3 to 0.4 µm
d) 0.4 to 0.5 µm

Answer & Explanations

Answer: b
Explanation: The values of surface finish range from 0.2 to 0.3 µm.

31. What are the values of voltages used for better surface quality?
a) 1 – 2 V
b) 2 – 3 V
c) 3 – 5 V
d) 5 – 8 V

Answer & Explanations

32. What are the machining speeds recommended for high surface quality?
a) 1 – 250 mm/min
b) 250 – 500 mm/min
c) 500 – 750 mm/min
d) 750 – 100 mm/min

Answer & Explanations

Answer: b
Explanation: The machining speeds recommended for high surface quality are between 250 and 500 mm/min in ECG.

33. What are the applications of Electro chemical grinding process?
a) Milling the material
b) Tool and cutter sharpening
c) Cutting off
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: The applications of electro chemical grinding are milling, grinding, cutting off, sawing, tool and cutter sharpening.

34. What are the advantages of machining in Electro chemical grinding?
a) Good surface quality
b) Absence of distortion
c) Longer wheel life
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: Good surface quality, absence of distortion, longer wheel life etc.., are some advantages of Electro chemical grinding.

35. Which of the following are the disadvantages of ECG process?
a) High capital cost
b) Limited to conductive materials
c) Corrosive nature
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: High capital cost, limited to conductive materials, corrosive nature etc.., are some disadvantages of ECG.

36. State whether the following statement is true of false regarding ECG process.
“In ECG process, filtering and disposal of electrolyte is not necessary.”
a) True
b) False

Answer & Explanations

Answer: b
Explanation: Main disadvantage of ECG is to filter and dispose the electrolyte used in the process.

37. What is the full form of ECH in the advanced machining processes?
a) Electro chemical honing
b) Electro chemical hammering
c) Electro chlorinated hammering
d) Electro chlorinated honing

Answer & Explanations

Answer: a
Explanation: The full form of ECH in the advanced machining processes is Electro chemical honing.

38. Which of the following mechanisms are used in the hybrid machining of ECH?
a) Electro chemical dissolution
b) Mechanical abrasion
c) Electro chemical dissolution & Mechanical abrasion
d) None of the mentioned

Answer & Explanations

Answer: c
Explanation: MA and ECD are used in material removal of the hybrid process of ECH.

39. ECH has __________ material removal rates than conventional honing or the internal cylindrical grinding.
a) Lower
b) Higher
c) Same
d) All of the mentioned

Answer & Explanations

Answer: b
Explanation: Electro chemical honing has higher material removal rates than conventional honing and the internal cylindrical grinding processes.

40. Majority of the material is removed in which phase of ECH?
a) Electro chemical dissolution
b) Mechanical abrasion
c) Electro chemical dissolution & Mechanical abrasion
d) None of the mentioned

Answer & Explanations

Answer: a
Explanation: Majority of the material in Electro chemical honing is removed in electro chemical dissolution phase.

41. Which of the following electrolytes is used for ECH process?
a) Sodium chloride
b) Sodium nitrate
c) Hydrochloric acid
d) Sulphuric acid

Answer & Explanations

Answer: b
Explanation: Sodium nitrate (240 g/L) is mostly used than Sodium chloride (120 g/L) and other acid electrolytes in Electro chemical honing.
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42. What is the value of electrolytic temperature maintained in ECH?
a) 18 ᵒC
b) 28 ᵒC
c) 38 ᵒC
d) 48 ᵒC

Answer & Explanations

Answer: c
Explanation: The value of the temperature of the electrolytic solution that is used in Electro chemical honing process is about 38 ᵒC.

43. What is the value of pressure of the electrolytic solution in ECH process?
a) 1 kPa
b) 10 kPa
c) 100 kPa
d) 1000 kPa

Answer & Explanations

Answer: d
Explanation: The value of the pressure of the electrolytic solution maintained in Electro chemical process is about 1000 kPa.

44. What is the flow rate of the electrolytic solution used in ECH process?
a) 85 L/min
b) 95 L/min
c) 105 L/min
d) 115 L/min

Answer & Explanations

Answer: b
Explanation: The rate of the electrolytic solution used in Electro chemical honing process is about 95 L/min.

45. What are the voltage values used in the process of ECH?
a) 0.1 to 1 V
b) 1 to 5 V
c) 6 to 30 V
d) 40 to 80 V

Answer & Explanations

Answer: c
Explanation: The voltage values used in ECH range from 6 to 30 V.

46. What are the current density values that are used in ECH process?
a) 165 A/cm2
b) 235 A/cm2
c) 385 A/cm2
d) 465 A/cm2

Answer & Explanations

Answer: d
Explanation: The current density values that are used in the process of Electro chemical honing are about 465 A/cm2.

47. State whether the following statement is true or false about ECH process.
“In ECH, improper electrolytic distribution will have no effect on any component.”
a) True
b) False

Answer & Explanations

Answer: b
Explanation: Improper electrolytic distribution leads to geometric irregularities and errors in the process of Electro chemical honing.

48. The machining system employs which type of abrasive stone for removal of material?
a) Pulsating
b) Vibrating
c) Reciprocating
d) All of the mentioned

Answer & Explanations

Answer: c
Explanation: The machining system of the Electro chemical honing process employs a reciprocating abrasive stone for the removal of material.

49. What is the value of gap maintained in ECH?
a) 0.025 to 0.075 mm
b) 0.075 to 0.250 mm
c) 0.250 to 0.750 mm
d) 0.750 to 2.50 mm

Answer & Explanations

Answer: b
Explanation: The value of gap maintained in electro chemical honing is between 0.076 and 0.250.

50. How much faster is MRR in ECH when compared to the conventional honing?
a) 1 to 2 times
b) 2 to 3 times
c) 3 to 5 times
d) 5 to 8 times

Answer & Explanations

Answer: c
Explanation: MRR in ECH is nearly 3 to 5 times faster than conventional honing.

51. How much faster is MRR in ECH when compared to the conventional internal grinding?
a) 2 times
b) 4 times
c) 6 times
d) 8 times

Answer & Explanations

Answer: b
Explanation: Material removal rate in ECH is nearly 4 times faster than that of the internal cylindrical grinding.
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52. What are the tolerances that are achieved using ECH process?
a) ± 0.001 mm
b) ± 0.002 mm
c) ± 0.003 mm
d) ± 0.004 mm

Answer & Explanations

Answer: c
Explanation: The value of the tolerances that are achieved during machining in ECH is about ± 0.003 mm.

53. What are the surface roughness values obtained while we use ECH process?
a) 0.1 to 0.2 µm
b) 0.2 to 0.8 µm
c) 0.8 to 1.6 µm
d) 1.6 to 3.2 µm

Answer & Explanations

Answer: b
Explanation: The value of the surface roughness range from 0.2 to 0.8 µm.

54. State whether the following statement is true or false regarding applications of ECH.
“In ECH, the roundness errors are reduced compared to other processes.”
a) True
b) False

Answer & Explanations

Answer: a
Explanation: As the tool rotates and reciprocates the roundness errors are reduced in electro chemical honing process.

55. Tool reciprocation can be used to reduce which of the following effects on work piece?
a) Taper
b) Waviness
c) Taper & Waviness
d) None of the mentioned

Answer & Explanations

Answer: c
Explanation: The tool reciprocation in Electro chemical honing is used to reduce taper and waviness errors.

56. State whether the following statement is true or false regarding the process of ECH.
“In ECH, the electro chemical dissolution phase introduces stresses.”
a) True
b) False

Answer & Explanations

Answer: b
Explanation: Electro chemical dissolution produces no stresses and automatically deburrs the part in Electro chemical honing process.

57. What is the full form of ECS in the advanced machining processes?
a) Electro chemical superfinishing
b) Electro chemical scribing
c) Electron cluster scribing
d) Electron cluster superfinishing

Answer & Explanations

Answer: a
Explanation: The full form of ECS in the advanced machining processes is Electro chemical superfinishing.

58. Which of the mechanisms combine to form this hybrid process of ECS?
a) Electro chemical dissolution
b) Mechanical scrubbing
c) Electro chemical dissolution & Mechanical scrubbing
d) None of the mentioned

Answer & Explanations

Answer: c
Explanation: Electro chemical dissolution and mechanical scrubbing combined in the hybrid process of ECS.

59. How much amount of burr is produced in the process of ECS?
a) 10 %
b) 20 %
c) 50 %
d) No burr produced

Answer & Explanations

Answer: d
Explanation: Burr free components are produced in the process of Electro chemical superfinishing due to electro chemical dissolution.

60. MRR are reduced by how much amount in the presence of the oxide film?
a) 10 %
b) 30 %
c) 50 %
d) 70 %

Answer & Explanations

Answer: c
Explanation: Material removal rates are reduced by 50 % in the presence of the film in Electro chemical superfinishing.

61. What are the tolerance values obtained in the ECS process?
a) ± 0.003 mm
b) ± 0.013 mm
c) ± 0.023 mm
d) ± 0.033 mm

Answer & Explanations

Answer: b
Explanation: The tolerance values obtained in the Electro chemical superfinishing process are about ± 0.013 mm on the diameter.

62. What are the values of roundness and straightness obtained from machining using ECS?
a) 0.001 mm
b) 0.003 mm
c) 0.007 mm
d) 0.013 mm

Answer & Explanations

Answer: c
Explanation: The values of roundness and straightness obtained from machining by Electro chemical superfinishing process is about 0.007 mm.

63. Which of the following are the process variables related to ECS?
a) Gap voltage
b) Electrolyte type
c) Concentration
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: Gap voltage, electrolyte type, concentration and temperature are some of the variable related to Electro chemical superfinishing.

64. Which of the following affect the process performance of Mechanical scrubbing?
a) Stone pressure
b) Oscillating frequency
c) Amplitude
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: Stone pressure, oscillating frequency and amplitude affect the mechanical scrubbing in the process of Electro chemical superfinishing.

65. High electro chemical dissolutions occur at which type of current densities?
a) Very Low
b) Low
c) Moderate
d) High

Answer & Explanations

Answer: d
Explanation: High electro chemical dissolutions occur at high current densities in the process of Electro chemical superfinishing.

66. Rise in different parameters related to the MS and ECD lead to ___________ material removal rates.
a) Increase in
b) Decrease in
c) Normal
d) All of the mentioned

Answer & Explanations

Answer: a
Explanation: A rise in the scrubbing speed, voltage, and duty cycle would lead to an increase in MRR.

67. What is the full form of ECB in the advanced machining processes?
a) Electro chemical buffing
b) Electro chemical blasting
c) Electron cluster blasting
d) Electron cluster briefing

Answer & Explanations

Answer: a
Explanation: The full form of ECB is Electro chemical buffing in the advanced machining processes.

68. Compared to conventional mechanical buffing Electro chemical buffing is a __________
a) Slower process
b) Faster process
c) Same speed process
d) None of the mentioned

Answer & Explanations

Answer: b
Explanation: Electro chemical buffing process is a faster machining process when compared to the conventional mechanical buffing.

69. Which of the following electrolytes are used ECB process?
a) Sodium chloride solution
b) Sodium nitrate solution
c) Sodium chloride & nitrate solution
d) None of the mentioned

Answer & Explanations

Answer: c
Explanation: Sodium chloride and sodium nitrate are the electrolytes that are used for machining purpose in the process of Electro chemical buffing.

70. What can be the concentration of Sodium chloride used in ECB?
a) 0.1 – 0.5 g/L
b) 1 – 5 g/L
c) 10 – 50 g/L
d) 100 – 500 g/L

Answer & Explanations

Answer: d
Explanation: The concentration of sodium chloride solution used for machining in ECB is about 100 – 500 g/L.

71. What are the values of the current densities used in ECB process?
a) 0.01 – 0.7 A/cm2
b) 0.1 – 7 A/cm2
c) 1 – 14 A/cm2
d) 21 – 42 A/cm2

Answer & Explanations

Answer: b
Explanation: The current densities used in the process of ECB range between 0.1 and 7 A/cm2.
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72. What are the values of buffing speeds used in ECB process?
a) 0.1 – 0.6 m/s
b) 1 – 6 m/s
c) 10 – 16 m/s
d) 100 – 600 m/s

Answer & Explanations

Answer: b
Explanation: The value of the buffing speed in Electro chemical buffing is about 1 – 6 m/s.

73. What are the values of contact pressures used in ECB process?
a) 1 – 6 g
b) 10 – 60 g
c) 100 – 600 g
d) 1000 – 6000 g

Answer & Explanations

Answer: c
Explanation: The values of contact pressure used in the ECB process are between 100 and 600 g.

74. What are the values of electrolyte flow rates used in ECB process?
a) 1 – 10 L/min
b) 10 – 100 L/min
c) 100 – 1000 L/min
d) 1000 – 10000 L/min

Answer & Explanations

Answer: a
Explanation: The values of electrolyte flow rates used in ECB process range between 1 – 10 L/min.

75. Which of the following factors control the polishing speed in the process of ECB?
a) Current density
b) Electrolyte type
c) Work piece material
d) All of the mentioned

Answer & Explanations

Answer: d
Explanation: The factors that control the polishing speed are current density, electrolyte time, work piece material.

76. Which of the following electrolytes can be used for high speed polishing?
a) Sodium chloride
b) Sodium nitrate
c) Sodium chloride & Sodium nitrate
d) None of the mentioned

Answer & Explanations

Answer: a
Explanation: Sodium chloride electrolyte can be used for high speed polishing in Electro chemical buffing process.

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