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Machining Processes MCQ Set 1

1. 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

View Answer

Answer: c [Reason:] 1 faraday equals to approximately 96500 C.

2. Of 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

View Answer

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

3. 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

View Answer

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

4. State whether 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

View Answer

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

5. 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

View Answer

Answer: b [Reason:] In Electrochemical machining, gap increases proportional to the square root of time.

6. At constant feed rates what happens to gap thickness?
a) Increases
b) Decreases
c) Becomes constant
d) None of the mentioned

View Answer

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

7. 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

View Answer

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

8. 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

View Answer

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

9. 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

View Answer

Answer: a [Reason:] Decrease in feed rate lead to wider gap thickness in ECM drilling.

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

View Answer

Answer: c [Reason:] Sparking or short circuit occurs when gap is too small.

Machining Processes MCQ Set 2

1. 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

View Answer

Answer: b [Reason:] Pressure of electrolyte used in ECDB is maintained between 0.3 to 0.5 MPa.

2. 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

View Answer

Answer: c [Reason:] Value of voltage used in ECDB process ranges from 12 to 24 V.

3. 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

View Answer

Answer: b [Reason:] Current densities used in ECDB process range between 5 – 10 A/cm2.

4. Which of the following electrolyte can be used for deburring process in ECDB?
a) NaNO2
b) NaNO3
c) NaCl
d) All of the mentioned

View Answer

Answer: d [Reason:] Sodium nitrite, sodium nitrate and sodium chloride are the electrolytes used in ECDB process.

5. 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

View Answer

Answer: c [Reason:] The inter electrode gap maintained in ECDB process, range between 0.30 – 0.50 mm.

6. 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

View Answer

Answer: b [Reason:] In ECDB, the tool tip should overlap the machined area by 1.5 to 2 mm in order to produce a proper radius.

7. 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

View Answer

Answer: d [Reason:] All the materials mentioned above, can be machined using ECDB process.

8. In ECDB process, rotating and feeding the tool electrode _____ the deburring process.
a) Enhances
b) Degrades
c) Damages
d) All of the mentioned

View Answer

Answer: a [Reason:] Rotating and feeding the tool in ECDB process, enhances the process of deburring.

9. 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

View Answer

Answer: d [Reason:] ECDB ensures the removal of burrs art required accuracy, uniformity, proper radius and clean edges.

10. 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

View Answer

Answer: Increased product quality and reliability, reduced labour costs, elimination of costly hand deburring etc.., are some of the advantages of ECDB.

11. State whether following statement is true or false regarding the advantages of ECDB.
“In ECDB, automation does not contribute to productivity.”
a) True
b) False

View Answer

Answer: b [Reason:] Electrochemical deburring can be automated for higher productivity.

Machining Processes MCQ Set 3

1. Which of the following are the applications of EBM?
a) Hole drilling
b) Slotting
c) Perforation of thin sheets
d) All of the mentioned

View Answer

Answer: d [Reason:] Drilling, perforation of thin sheets, slotting and integrated circuit fabrication are some of the applications of Electron beam machining.

2. What is the value of largest diameter of the hole drilled on EBM?
a) 0.5 mm
b) 1.0 mm
c) 1.5 mm
d) 2.0 mm

View Answer

Answer: c [Reason:] The maximum value of diameter that can be drilled using Electron beam machining is about 1.5 mm.

3. What is the value of maximum depth of the hole drilled on EBM?
a) 10 mm
b) 20 mm
c) 30 mm
d) 40 mm

View Answer

Answer: c [Reason:] Value of the maximum depth that can be drilled using Electron beam machining is about 10 mm.

4. What is the range of depth-to-diameter ratio in Electron beam machining?
a) 2:5 to 2:11
b) 1:1 to 1:15
c) 3:4 to 3:20
d) 4:5 to 4:19

View Answer

Answer: b [Reason:] The depth to diameter ratio in Electron beam machining will vary between 1:1 and 1:15.

5. How many holes can be produced in perforation of thin sheets using EBM?
a) 101 to 102
b) 102 to 103
c) 103 to 104
d) 104 to 105

View Answer

Answer: d [Reason:] Number of holes produced range from 104 to 105 per second in perforation using EBM.

6. What is the value of energy required for bond breaking?
a) 10 to 20kV
b) 20 to 30kV
c) 30 to 40kV
d) 40 to 50kV

View Answer

Answer: a [Reason:] Value of the beam energy used for breaking bonds or cross linking them range from 10 to 20kV.

7. What is the value of pulse time used in EBM?
a) 0.004 to 0.064 µs
b) 0.04 to 0.64 µs
c) 0.4 to 640 µs
d) 4 to 64000 µs

View Answer

Answer: d [Reason:] Value of the pulse time of beam ranges from 4 to 64000 µs.

8. What is the value of frequency used in EBM?
a) 0.001 – 0.016 Hz
b) 0.01 – 16 Hz
c) 0.1 – 16000 Hz
d) 10 – 1600 kHz

View Answer

Answer: c [Reason:] The frequency of the pulse range between 0.1 and 16000 Hz in Electron beam machining.

9. What is the tolerance value obtained in EBM?
a) ± 10 %
b) ± 20 %
c) ± 30 %
d) ± 40 %

View Answer

Answer: a [Reason:] The tolerances obtained in Electron beam machining is about ± 10 % of the depth of cut.

10. Which of the following are the advantages of EBM process?
a) Drilling rates
b) No distortion
c) High accuracy
d) All of the mentioned

View Answer

Answer: d [Reason:] The main advantages of Electron beam machining are high drilling rates, no mechanical distortion, high accuracy and repeatability.

11. There is no limitation imposed on which of the following factors in EBM?
a) Material ductility
b) Surface hardness
c) Surface reflectivity
d) All of the mentioned

View Answer

Answer: d [Reason:] In Electron beam machining, no limitation is imposed by work piece hardness, ductility, and surface reflectivity.

12. How much is the capital equipment cost of equipment used in EBM?
a) Very low cost
b) Low cost
c) Moderate cost
d) High cost

View Answer

Answer: d [Reason:] The capital equipment cost of the Electron beam machining is high compared to other machining processes.

13. How are the production times for a material in electron beam machining?
a) Very small
b) Small
c) Moderate
d) Long

View Answer

Answer: d [Reason:] In Electron beam machining, long production times are required due to the generation of vacuum in the chamber for machining purpose.

14. Which type of thin cast layer is produced when we use EBM?
a) Thin layer
b) Thick layer
c) No layer
d) All of the mentioned

View Answer

Answer: a [Reason:] Thin recast layer is produced in Electron beam machining which an added disadvantage to the machining process.

Machining Processes MCQ Set 4

1. 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

View Answer

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

2. State whether following statement is true or false.
“Using abrasive jet machining, wire cleaning and insulation stripping takes places without affecting the conductor.”
a) True
b) False

View Answer

Answer: a [Reason:] Without affecting the conductor, both stripping and cleaning are done, by using Abrasive jet machining.

3. 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

View Answer

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

4. 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

View Answer

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

5. 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

View Answer

Answer: d [Reason:] In Abrasive jet machining, the above mentioned materials can be machined, which are heat sensitive and brittle.

6. What is the amount of material utilizes when we machine parts using Abrasive jet machining?
a) Very low
b) Low
c) Medium
d) High

View Answer

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

7. 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

View Answer

Answer: d [Reason:] In Abrasive jet machining, tool changes are not required.

8. 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

View Answer

Answer: a [Reason:] In Abrasive jet machining, hardening is not experienced by the machined materials.

9. 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

View Answer

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

10. 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

View Answer

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

11. 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

View Answer

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

Machining Processes MCQ Set 5

1. What is the value of 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

View Answer

Answer: b [Reason:] High current densities, which range between 0.5 – 5 A/mm2 are used in ECM.

2. 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

View Answer

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

3. 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

View Answer

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

4. 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

View Answer

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

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

View Answer

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

6. State whether 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

View Answer

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

7. 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

View Answer

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

8. 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

View Answer

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

9. 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

View Answer

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

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

View Answer

Answer: b [Reason:] Positively charge particles are directed towards cathode, which is negatively charged.

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

View Answer

Answer: a [Reason:] Negatively charged particles are directed towards anode, which is positively charged.

Machining Processes MCQ Set 6

1. 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

View Answer

Answer: b [Reason:] Roller speed used can be up to 1.3 m/s.

2. 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

View Answer

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

3. 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

View Answer

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

4. 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

View Answer

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

5. 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

View Answer

Answer: a [Reason:] Axial oscillation motion of magnets takes with respect to work piece.

6. 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

View Answer

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

7. 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

View Answer

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

8. State whether 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

View Answer

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

9. On 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

View Answer

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

10. 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

View Answer

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

11. State whether 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

View Answer

Answer: a [Reason:] As the amplitude and frequency increases, rate of material removal increases.