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.
