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.
ybrid Electrochemical Processes
