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Machining Processes MCQ Set 1

1. Which of the following use ECM for different applications?
a) Gas turbines
b) Jet engines
c) Bio medical implants
d) All of the mentioned

View Answer

Answer: d [Reason:] ECM has its applications in industries such as gas turbines, jet engines, automobiles, medical etc.

2. 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

View Answer

Answer: d [Reason:] ECM can be used for die sinking, trepanning, drilling, contouring, grinding and profiling.

3. 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

View Answer

Answer: c [Reason:] ECM can be used for machining high strength alloys and hardened steels which led to many cost-saving applications.

4. ECM is used to _____ the sharp edges produced after rough cuts?
a) Enhance
b) Dull
c) Improve
d) None of the mentioned

View Answer

Answer: b [Reason:] Using deburring process through ECM, sharp edges are dulled, which are produced after rough cuts.

5. 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

View Answer

Answer: b [Reason:] ECM is usually characterized as low accuracy machining because of its wider machining gap.

6. 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

View Answer

Answer: a [Reason:] Electrolyte jet in micro ECM acts as the micro tool for machining.

7. 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

View Answer

Answer: b [Reason:] Micro ECM is used to machine micro parts which can be from micro scale to mesoscale in size.

8. Which of the following produces small indents and cavities using micro ECM?
a) Moving the work piece
b) Switching the pulse current
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Indentation and cavitation can be done using micro ECM by moving the work piece or switching the pulse current.

Machining Processes MCQ Set 2

1. Which of the following electrodes are used for machining spherical surfaces in Electro discharge machining?
a) Tubular electrodes
b) Flat electrodes
c) Cuboidal electrodes
d) All of the mentioned

View Answer

Answer: a [Reason:] Simple tubular electrodes are used to machine convex and concave spherical surfaces.

2. What are the values of dimensional accuracy obtained while machining spherical surfaces?
a) ± 1 µm
b) ± 3 µm
c) ± 5 µm
d) ± 7 µm

View Answer

Answer: a [Reason:] Dimensional accuracy of ± 1 µm is obtained while machining spherical surfaces using EDM.

3. What are the surface roughness values obtained while machining spherical surfaces using Electro discharge machining?
a) <0.1 µm
b) <0.3 µm
c) <0.5 µm
d) <0.7 µm

View Answer

Answer: a [Reason:] The surface roughness values obtained while machining of spherical surfaces are <0.1 µm in Electro discharge machining.

4. Which motion of tool is used for machining spherical surfaces in Electro discharge machining?
a) Oscillatory
b) Vibratory
c) Rotary
d) All of the mentioned

View Answer

Answer: c [Reason:] The rotary motion tool is used for machining spherical surfaces of conducting ceramic materials in EDM.

5. Which type of electrodes are used for milling application in Electro discharge machining process?
a) Tubular type electrodes
b) Cylindrical type electrodes
c) Flat type electrodes
d) Spherical type electrodes

View Answer

Answer: b [Reason:] Standard cylindrical electrodes are used for milling application in EDM process.

6. Which type of cavities can be machined using milling process by Electro discharge machining?
a) Complex cavities
b) Simple cavities
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Simple cavities and complex cavities are machined by successive NC sweeps of electrode over the desired path.

7. The simple electrodes are rotated at which speed for milling of work pieces in Electro discharge machining?
a) Very low
b) Low
c) Medium
d) High

View Answer

Answer: d [Reason:] Simple electrodes are rotated at high speeds for milling in Electro discharge machining same as that of conventional milling.

8. What happens to the dielectric flushing while milling tool is rotated at a high speed in EDM?
a) Improved
b) Worsen
c) Reduced
d) All of the mentioned

View Answer

Answer: a [Reason:] Milling by electro discharge machining enhances the dielectric flushing due to high speed rotation of tool.

9. State whether following statement is true or false regarding the applications of EDM.
“In EDM, milling process can machine complex shapes with sharp corners.”
a) True
b) False

View Answer

Answer: b [Reason:] EDM milling has a main limitation i.e.., it cannot machine complex shapes with sharp tools because of rotating tool.

10. Which of the following are the steps included in the die sinking process of EDM?
a) CAD of electrode
b) Electrode manufacturing
c) Programming for die sinking
d) All of the mentioned

View Answer

Answer: d [Reason:] Designing of electrode, then manufacturing, and programming of die sinking are the steps to be followed for die sinking process in EDM.

11. Wire EDM is a special form of Electro discharge machining which contains _____ electrode.
a) Continuously moving
b) Periodically moving
c) Discontinuously moving
d) All of the mentioned

View Answer

Answer: a [Reason:] Wire EDM is a special type of EDM which uses a continuously moving electrode for removal of material.

12. Which path of the components in wire EDM determines the path to be machined?
a) Horizontal worktable movement
b) Vertical worktable movement
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: a [Reason:] Horizontal movement of the work table determines the path to be machined in Wire Electro discharge machining.

13. Which of the following materials are machined using Wire Electro discharge machining?
a) Polycrystalline diamond
b) Cubic Boronitride
c) Matrix composites
d) All of the mentioned

View Answer

Answer: d [Reason:] Polycrystalline diamond (PCD), cubic boron nitride (CBN) and other matrix composites are the material than can be machined using wire EDM.

14. How much amount of burr is produce when we use Wire Electro discharge machining for machining of work pieces?
a) 10%
b) 20%
c) No burr
d) Small amount

View Answer

Answer: c [Reason:] In Wire Electro discharge machining no burr is produced without any distortion while machining work pieces.

15. Which of the following industries use wire EDM for different applications?
a) Chemical industry
b) Aerospace industry
c) Automobile industry
d) All of the mentioned

View Answer

Answer: d [Reason:] Industries such as chemical, aerospace, automobile, nuclear etc.., use wire EDM for wide variety of applications in their industries.

Machining Processes MCQ Set 3

1. Which one among the following, is the most important factor in determining the tool wear?
a) Melting point
b) Boiling point
c) Power supplied
d) Feed rate

View Answer

Answer: a [Reason:] In EDM, melting point is the most important factor in determining the tool wear.

2. Electrode wear ratios can be expressed as, which of the following wears?
a) End wear
b) Side wear
c) Corner wear
d) All of the mentioned

View Answer

Answer: d [Reason:] Electrode wear ratios are expressed as end wear, corner wear, side wear and volume wear.

3. The term no wear in EDM occurs when electro-to-work piece wear ratio is _____
a) <1%
b) <3%
c) <5%
d) <10%

View Answer

Answer: a [Reason:] In Electro discharge machining, no wear is the term used when the electrode-to-work piece ratio is less than 1%.

4. Which of the following are the other factors that influence the electrode wear?
a) Voltage
b) Current
c) Electrode material
d) All of the mentioned

View Answer

Answer: d [Reason:] In EDM, electrode wear depends on the factors such as voltage, current, electrode material and polarity.

5. State whether following statement is true or false regarding wear in EDM.
“In EDM, electrode wear is less dominant when it comes to micromachining applications.”
a) True
b) False

View Answer

Answer: b [Reason:] Electrode wear is more when it comes to micromachining applications in EDM.

6. State whether following statement is true or false regarding wear in EDM.
“In EDM, corner wear ratio does not depend on type of electrode material.”
a) True
b) False

View Answer

Answer: b [Reason:] In EDM, corner wear ratio depend on the material of electrode used.

7. In Electro discharge machining, highest wear ratio is associated with which type of melting point?
a) Low
b) Medium
c) High
d) Very high

View Answer

Answer: a [Reason:] In Electro discharge machining, lowering of the melting point of electrode material results in high wear ratio.

8. Which of the following is not a function of dielectric in EDM?
a) Flush particles
b) Cool the section
c) Maintain voltage
d) Provide insulation

View Answer

Answer: c [Reason:] Flushing particles, providing insulation and cooling the sections that are heated, are the functions of dielectric.

9. Which of the following are the main requirements of dielectric fluids?
a) Viscosity
b) High flash point
c) Minimum odour
d) All of the mentioned

View Answer

Answer: d [Reason:] Adequate viscosity, high flash point, oxidation stability, minimum odour, low cost and good electrical discharge are the main requirements of dielectric fluids.

10. Which of the following can be used as dielectric fluids in EDM?
a) Kerosene
b) Silicon fluids
c) Distilled water
d) All of the mentioned

View Answer

Answer: d [Reason:] The dielectric fluids used are kerosene, silicon fluid, ethylene glycol, water in emulsions and distilled water.

11. In EDM, inadequate flushing will not result in which of the following consequences?
a) Arcing
b) Debris removal
c) Decrease electrode life
d) Increased production time

View Answer

Answer: b [Reason:] Inadequate flushing in Electro discharge machining results in less removal or no removal of debris.

12. Which methods below, are used for introducing the dielectric in machining gap?
a) Normal flow
b) Reverse flow
c) Jet flushing
d) All of the mentioned

View Answer

Answer: d [Reason:] Four methods namely normal flow, reverse flow, jet flushing and immersion flushing are used for introducing dielectric.

13. Few large holes are _____ than many small flushing holes in Electro discharge machining.
a) Worse
b) Better
c) Well
d) None of the mentioned

View Answer

Answer: a [Reason:] Many small holes are better than a few large holes in machining thorough the EDM process.

14. State whether following statement is true or false regarding the dielectric in EDM.
“In EDM, flushing through the tool is more preferred than side flushing.”
a) True
b) False

View Answer

Answer: a [Reason:] Flushing through the tool is preferred than side flushing for deep cuts.

15. In Electro discharge machining, which type of dielectric flow mentioned below is desirable?
a) Unsteady flow
b) Steady flow
c) Unstable flow
d) None of the mentioned

View Answer

Answer: b [Reason:] In EDM, steady dielectric flow on the entire electrode-work piece interfaces is most desirable.

Machining Processes MCQ Set 4

1. 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

View Answer

Answer: d [Reason:] All the applications mentioned above can be fulfilled using MAF.

2. 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

View Answer

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

3. 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

View Answer

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

4. 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

View Answer

Answer: b [Reason:] Ceramic balls are placed in between drive shaft and float.

5. 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

View Answer

Answer: a [Reason:] Abrasives are used for the polishing and finishing operations of the parts, in Magnetic abrasive finishing.

6. State whether 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

View Answer

Answer: a [Reason:] Since the forces exerted are very small, polishing is very fine.

7. 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

View Answer

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

8. 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

View Answer

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

9. State whether 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

View Answer

Answer: b [Reason:] Removed burrs without lowering the accuracy are obtained using MAF.

10. 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

View Answer

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

Machining Processes MCQ Set 5

1. 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

View Answer

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

2. 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

View Answer

Answer: d [Reason:] All the parameters mentioned above come under Abrasive water jet machining.

3. 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

View Answer

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

4. 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

View Answer

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

5. When compared to sand, how much effective is garnet as abrasive material in AWJM?
a) 20%
b) 30%
c) 40%
d) 50%

View Answer

Answer: b [Reason:] Garnet, which is commonly used abrasive material is nearly 30% more effective than sand in Abrasive water jet machining.

6. State whether 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

View Answer

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

7. 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

View Answer

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

8. 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

View Answer

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

9. 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

View Answer

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

10. 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

View Answer

Answer: a [Reason:] Stand-off distance in Abrasive water jet machining will vary between 1 – 2 mm.

11. Impact angle in Abrasive water jet machining range between which of the following values?
a) 0&#176 to 10&#176
b) 10&#176 to 30&#176
c) 30&#176 to 90&#176
d) 90&#176 to 100&#176

View Answer

Answer: c [Reason:] Machine impact angle in AWJM will range between 30&#176 to 90&#176.

12. 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

View Answer

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

13. 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

View Answer

Answer: b [Reason:] Value of depth of cut in AWJM ranges between 2 to 250 mm.

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