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Machining Processes MCQ Set 1

1. 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

View Answer

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

2. 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

View Answer

Answer: d [Reason:] All the factors mentioned above, are responsible for different qualities of surface finish.

3. State whether 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

View Answer

Answer: b [Reason:] In CHM, surfaces do not have regular lay pattern.

4. Which of the following defects cannot be altered or eliminated using CHM?
a) Waviness
b) Surface imperfections
c) Scratches
d) Dents

View Answer

Answer: b [Reason:] Using CHM, surface imperfections cannot be eliminated.

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

View Answer

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

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

View Answer

Answer: d [Reason:] In Chemical milling, tolerance increases when machining depth increases.

7. 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

View Answer

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

8. 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%

View Answer

Answer: a [Reason:] Tolerances of ± 10% of cut width are achieved using CHM.

9. 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

View Answer

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

10. 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

View Answer

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

11. 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

View Answer

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

12. 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

View Answer

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

13. State whether 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

View Answer

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

Machining Processes MCQ Set 2

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

View Answer

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

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

View Answer

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

3. 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

View Answer

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

4. State whether 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

View Answer

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

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

View Answer

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

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

View Answer

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

7. 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

View Answer

Answer: d [Reason:] All of the advantages mentioned above, are obtained using CHM.

8. 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

View Answer

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

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

View Answer

Answer: b [Reason:] Decorative finishes are obtained when we use CHM.

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

View Answer

Answer: b [Reason:] Low scrapes rates around 3% are obtained when we use Chemical milling process.

Machining Processes MCQ Set 3

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

View Answer

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

2. 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

View Answer

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

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

View Answer

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

4. Which of the following is most popular application for weight reduction of aerospace components?
a) Shallow cuts
b) Deep cuts
c) Very deep cuts
d) None of the mentioned

View Answer

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

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

View Answer

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

6. 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

View Answer

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

7. 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

View Answer

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

8. 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

View Answer

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

9. 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

View Answer

Answer: b [Reason:] Removal of thin surfaces from forgings and casting takes place, prior to penetration depth inspection.

10. State whether 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

View Answer

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

Machining Processes MCQ Set 4

1. 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

View Answer

Answer: d [Reason:] All the factors mentioned above, are the limitations of Chemical milling process.

2. 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

View Answer

Answer: c [Reason:] Very shallow depths of value 12.27 mm, are obtained when we use CHM.

3. 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

View Answer

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

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

View Answer

Answer: a [Reason:] Metallurgic homogenous surfaces are needed for chemical milling to take place.

5. 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

View Answer

Answer: c [Reason:] As there are porous castings, there would be pores on the surface which lead to uneven surfaces.

6. State whether following statement regarding the limitations of CHM.
“Welded areas etch, at a rate that is same as base metal.”
a) True
b) False

View Answer

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

7. 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

View Answer

Answer: b [Reason:] Absence of residual stresses produce unfavorable fatigue strength, unlike to the processes that induce compressive residual stresses.

8. Which of the following, indicate the accuracy of scribing by Chemical milling process?
a) Unlimited
b) Boundless
c) Infinite
d) None of the mentioned

View Answer

Answer: d [Reason:] Scribing accuracy is limited in CHM process due to uneven surface finish.

9. 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

View Answer

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

10. 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

View Answer

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

Machining Processes MCQ Set 5

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

View Answer

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

2. 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

View Answer

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

3. 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

View Answer

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

4. 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

View Answer

Answer: d [Reason:] All the factors mentioned above, will have direct impact due to above process parameters.

5. 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

View Answer

Answer: b [Reason:] Maskant material coatings should have a thickness, which range between 0.025 – 0.13 mm.

6. 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

View Answer

Answer: d [Reason:] All the materials mentioned above, can be used as maskant materials.

7. State whether 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

View Answer

Answer: b [Reason:] Material removal rate also depends on uniformity of the solution temperature.

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

View Answer

Answer: c [Reason:] Chemical milling is independent of frequency distribution.

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

View Answer

Answer: d [Reason:] In castings, as grain size increases, surface roughness increases.

10. 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

View Answer

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

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

View Answer

Answer: b [Reason:] In Chemical milling, softer materials need low etching rates.

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

View Answer

Answer: d [Reason:] In Chemical milling, harder materials need higher etching rates.

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

View Answer

Answer: a [Reason:] High etching rates are results in low surface roughness values.