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Machining Processes MCQ Set 1

1. Which of the following are the tools required for Chemical milling?
a) Maskants
b) Etchants
c) Scribing plates
d) All of the mentioned

View Answer

Answer: d [Reason:] All the components mentioned above, are required to carry out Chemical milling process.

2. 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

View Answer

Answer: a [Reason:] In CHM, maskants are used to protect the work piece from chemical agents.

3. 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

View Answer

Answer: d [Reason:] All the materials mentioned above, can be used for making maskants.

4. 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

View Answer

Answer: d [Reason:] All the properties mentioned above, should be possessed by the maskants.

5. 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

View Answer

Answer: d [Reason:] Maskants can be applied to work piece, by the above mentioned means.

6. State whether following statement is true or false regarding maskants.
“After etching, maskants should be removed easily and inexpensively.”
a) True
b) False

View Answer

Answer: a [Reason:] After etching is done, maskants should be removed easily by inexpensive means.

7. 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

View Answer

Answer: d [Reason:] We will have the advantages which are mentioned above, if we use photo resist masking.

8. 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

View Answer

Answer: d [Reason:] Tolerance value of ± 0.179 mm, will be obtained, when we use cut and peel mask method.

9. 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

View Answer

Answer: c [Reason:] Tolerance value of ± 0.077 mm, will be obtained, when we use silk screen resist method.

10. 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

View Answer

Answer: a [Reason:] Tolerance value of ± 0.013 mm, will be obtained, when we use photo resist method.

11. 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

View Answer

Answer: d [Reason:] In CHM, etchants are used for the above mentioned factors.

12. 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

View Answer

Answer: a [Reason:] Etchants control the H2 absorption in Ti alloys.

13. 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

View Answer

Answer: a [Reason:] Scribing plates defines the areas that are to be exposed for removal of material.

14. 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

View Answer

Answer: d [Reason:] All the guides mentioned above, can be used for scribing process.

15. 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

View Answer

Answer: d [Reason:] The accessories mentioned above are included in the tooling of Chemical milling.

Machining Processes MCQ Set 2

1. What fraction of tool will always be in contact with the work piece?
a) Half
b) Full
c) No contact
d) Quarter

View Answer

Answer: c [Reason:] Tool does not have any contact with the work piece in Electro chemical machining.

2. How much amount of wear is present in the tool used in Electrochemical machining?
a) No wear
b) Low
c) Medium
d) High

View Answer

Answer: a [Reason:] The tool wear is absent in the tool used in ECM, since tool has no contact with the work piece.

3. Compared to other processes, machining is done at _____ voltages for high rates of material removal.
a) Low
b) Medium
c) High
d) very low

View Answer

Answer: c [Reason:] In ECM, machining is done at low voltages, when compared to other processes.

4. Very small dimensions, up to which value can be controlled using ECM?
a) 0.01 mm
b) 0.05 mm
c) 0.07 mm
d) 0.12 mm

View Answer

Answer: b [Reason:] Due to less electrode gap very small dimensions up to 0.05 mm can be controlled.

5. Complicated profiles can be machined in how many operations in Electrochemical machining?
a) Single
b) Double
c) Triple
d) Multiple

View Answer

Answer: a [Reason:] One of the main advantage of ECM is, complicated profiles can be machined in a single operation itself.

6. How much amount of thermal damage occurs to the work piece?
a) Small
b) Large
c) No thermal damage
d) Negligible amount

View Answer

Answer: c [Reason:] As the temperatures are very low, no thermal damage occurs to the work piece material.

7. Which of the following materials can be machined using ECM?
a) Hard nonconductive materials
b) Hard conductive materials
c) All nonconductive materials
d) None of the mentioned

View Answer

Answer: b [Reason:] Hard conductive materials can be machined and nonconductive materials cannot be machined using ECM.

8. What are the requirements of labour for machining purpose in Electrochemical machining?
a) Low
b) Medium
c) High
d) Very high

View Answer

Answer: a [Reason:] In electrochemical machining, labour requirements are low compared to conventional or traditional machining practices.

9. How much amount of energy is consumed in Electro chemical machining?
a) Very small
b) Small
c) Medium
d) Large

View Answer

Answer: d [Reason:] Very huge amount of energy is required for ECM, which is nearly 100 times required for turning or drilling of steel.

10. How are material removal rates of ECM, when compared to that of conventional methods?
a) Slower
b) Faster
c) Same
d) None of the mentioned

View Answer

Answer: a [Reason:] In ECM, rates of material removal are slow compared to conventional methods.

11. State whether following statement is true or false regarding the limitations of ECM.
“In ECM, cleaning and oiling of work piece need not be done after machining.”
a) True
b) False

View Answer

Answer: b [Reason:] Work piece needs to be cleaned and oiled just after the machining is done.

12. Which of the following are the limitations of electro chemical machining?
a) Removal of hydrogen
b) Handling the electrolyte
c) Energy consumption
d) All of the mentioned

View Answer

Answer: d [Reason:] Removal of hydrogen, handling and containing the electrolyte and energy consumption are some of the limitations of ECM.

13. State whether following statement is true or false regarding the limitations of ECM.
“In electrochemical machining, duplicating the tool is easier.”
a) True
b) False

View Answer

Answer: b [Reason:] Duplication of tool is difficult in ECM, since it has side machining effects.

14. Electro chemical machining process cannot produce which of the following mentioned below?
a) Drilled holes
b) Deburred edges
c) Sharp edges
d) All of the mentioned

View Answer

Answer: c [Reason:] Electro chemical machining cannot produce sharp internal or external edges.

15. Pumping of electrolyte through the narrow gaps causes, which type of forces on tool and work piece?
a) Large
b) Small
c) Negligible
d) No force

View Answer

Answer: a [Reason:] Electrolyte pumping through the narrow gaps gives rise to a large amount of forces on tool and work pieces.

Machining Processes MCQ Set 3

1. If electro chemical machining is applied under appropriate conditions, how much amount of health dangers can occur?
a) Small amount
b) Limited amount
c) Large amount
d) Very large amount

View Answer

Answer: b [Reason:] Occupational health dangers are limited if ECM is done at appropriate conditions.

2. Which of the following are some of the bad impacts on environment while using ECM?
a) Electrolyte splashing
b) Toxic gases release
c) Precipitation of solid matters
d) All of the mentioned

View Answer

Answer: d [Reason:] Electrolyte splashing, precipitation of solid matter, and toxic gas release is very harmful to the environment.

3. Which of the following parts of the body can be contaminated while using ECM?
a) Skin
b) Eyes
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Contamination of skin and eyes may occur due to electrolyte splashing and toxic gas release.

4. During deburring and die sinking which of the following electrolyte gives high surface quality and accuracy?
a) NaNO3
b) HNO3
c) NaCl
d) All of the mentioned

View Answer

Answer: a [Reason:] By using NaNO3, deburring and die sinking can be done with more accuracy and high qualities are obtained.

5. Dissolution of metal containing chrome results in which of the toxic compounds?
a) Toxic chromate
b) Ammonia
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Dissolution of metal containing chromate results nitrate reduction at cathode tool, which in turn produces toxic chromate and ammonia.

6. Slurries mixing with toxic compounds produce, which of the following?
a) Solid precipitates
b) Liquid solutions
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: a [Reason:] Slurries which mix with toxic compounds such as chromate and ammonia precipitates solid matter in the electrolyte solution.

7. What should be done to the electrolyte with solid matter?
a) Can be reused
b) Disposed off
c) No disposing is necessary
d) All of the mentioned

View Answer

Answer: b [Reason:] The electrolyte which contain the solid precipitates needs to be disposed immediately, in order to avoid any damage to the environment.

8. State whether following statement is true or false regarding the environmental impacts of ECM.
“In ECM, accumulation of toxic compounds is due to nitrate reduction at tool cathode.”
a) True
b) False

View Answer

Answer: a [Reason:] When chromate containing metals dissolute, nitrate accumulate at cathode tool, which result in toxic chromate and ammonia compounds.

Machining Processes MCQ Set 4

1. Which of the following come under the main components of ECM?
a) Feed control system
b) Work piece holding devices
c) Electrolyte supply system
d) All of the mentioned

View Answer

Answer: d [Reason:] The main components of Electro chemical machining include feed control system, electrolyte supply system, power supply unit, work piece holding devices.

2. Feed control system is responsible for which action in ECM?
a) Giving feed to tool
b) Electrolyte supply
c) Power supply
d) None of the mentioned

View Answer

Answer: a [Reason:] Feed control system is used for feeding the tool at constant rate during equilibrium machining.

3. In ECM equipment, what is the role of electrolyte supply system?
a) Giving feed to tool
b) Electrolyte supply
c) Power supply
d) None of the mentioned

View Answer

Answer: b [Reason:] As the name itself indicates, electrolyte supply system is used to supply the electrolyte required for anodic dissolution.

4. What is the role of power supply unit in ECM equipment?
a) Giving feed to tool
b) Electrolyte supply
c) Power supply
d) None of the mentioned

View Answer

Answer: c [Reason:] In ECM, power supply unit is used to supply the machine current at constant dc voltage.

5. For large size machining, which type of facilities are used in ECM?
a) Semi-automated facilities
b) Automated facilities
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Automated and semi-automated facilities are used for large size machining.

6. Electrolyte supply system should concentrate on which of the following factors?
a) Pressure
b) Supply rate
c) Temperature
d) All of the mentioned

View Answer

Answer: d [Reason:] Electrolyte supply system should supply electrolyte at a given rate, temperature and pressure.

7. For high strength or rigidity, which type of coatings are recommended for metals?
a) Other metal coatings
b) Non-metallic coatings
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: b [Reason:] For high strength and rigidity, non-metallic coatings are recommended for metals.

8. What is the value of voltage that the power supply unit supplies for ECM?
a) 0.01 to 1 V
b) 2 to 30 V
c) 50 to 80 V
d) 100 to 160 V

View Answer

Answer: b [Reason:] Voltage supply required for ECM range between 2 to 30 V.

9. Between which of the following values, does the current range?
a) 0.002 to 0.01 A
b) 0.01 to 10 A
c) 50 to 10000 A
d) 105 to 106 A

View Answer

Answer: c [Reason:] In Electrochemical machining, current value ranges between 50 to 10000 A.

10. What are the values of current densities used in ECM?
a) 0.1 to 2 A/cm2
b) 5 to 500 A/cm2
c) 600 to 1000 A/cm2
d) 1200 to 2800 A/cm2

View Answer

Answer: b [Reason:] Current density values in ECM range between 5 to 500 A/cm2.

11. Which type of adjustment is to be done for gap voltages?
a) Continuous adjustment
b) Discontinuous adjustment
c) Periodic adjustment
d) All of the mentioned

View Answer

Answer: a [Reason:] In ECM, usually continuous adjustment of gap voltage is required.

12. Compared to the tool used in ECM, how should be the work piece size?
a) Greater than
b) Smaller than
c) Same as tool
d) None of the mentioned

View Answer

Answer: a [Reason:] By an oversize, work piece size is expected to be greater than tool size.

13. Which of the following factors are used to determine the tool geometry?
a) Required shape
b) Electrical conductivity
c) Tool feed rate
d) All of the mentioned

View Answer

Answer: d [Reason:] For determining a tool geometry we must specify some factors such as required shape of surface, tool feed rate, gap voltage, electrochemical machinability of the work material, electrolyte conductivity, and both electrodes’ polarization voltages.

14. Which of the following are the simplest methods for applying the insulation on tools?
a) Spraying
b) Dipping
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] In ECM, dipping or spraying are the simplest methods for insulating the tools.

15. State whether following statement is true or false regarding the tools of ECM.
“With computer integrated manufacturing (CIM), cathodes are produced at high costs and less accurately.”
a) True
b) False

View Answer

Answer: b [Reason:] Using CIM, cathodes are produced at low costs and more accurately.

Machining Processes MCQ Set 5

1. Electro chemical dissolution phase starts with the movement of ions between which two components?
a) Cathode and anode
b) Cathode and power source
c) Power source and anode
d) Power source and electrolyte

View Answer

Answer: a [Reason:] ECD phase occurs by the movement of ions between the two electrodes.

2. Better surface finish and higher accuracy depend on which of the factors below?
a) Chemical composition of electrolyte
b) Current density
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Proper chemical composition of electrolyte and proper current density are responsible for better surface finish and accuracy.

3. For alloys, which type of electrolyte is used in ECM?
a) Single component
b) Double component
c) Multi component
d) Triple component

View Answer

Answer: c [Reason:] Depending up on the elements in an alloy multi component electrolytes are used.

4. Nickel can be machined with 100% current efficiency, when current density value is _____.
a) 10 A/cm2
b) 25 A/cm2
c) 45 A/cm2
d) 80 A/cm2

View Answer

Answer: b [Reason:] Nickel is a metal suggested by Khayry, which can be machined at 100% current efficiency, if current density is 25 A/cm2.

5. When the electrolyte flow is low, what happens to the current efficiency?
a) Increases
b) Decreases
c) Remains same
d) Increase and then decrease

View Answer

Answer: b [Reason:] In ECM, if the electrolyte flow is low, current efficiency is reduced due to the accumulation of machining products within the gap.

6. When machining Ti, in Nacl electrolyte, what values of current efficiencies are obtained?
a) 10 – 20 %
b) 20 – 30 %
c) 30 – 50 %
d) 50 – 80 %

View Answer

Answer: a [Reason:] While machining Ti using NaCl electrolyte, current efficiencies of 10 – 20 percent are obtained.

7. State whether following statement is true or false about electrolyte in ECM.
“Machinability in ECM is enhanced, when electrolyte is heated.”
a) True
b) False

View Answer

Answer: a [Reason:] Machinability is increased, when electrolyte is heated, as heating increases the specific conductivity of the electrolyte.

8. In practice, what must be the temperature of electrolyte used in ECM?
a) 10 – 20oC
b) 20 – 40oC
c) 60 – 80oC
d) 80 – 100oC

View Answer

Answer: c [Reason:] Temperature of electrolyte used in ECM must not exceed 60 – 70oC.

9. What is the value of moderate level of pH of electrolyte used?
a) 1 – 2
b) 2 – 4
c) 4 – 10
d) All of the mentioned

View Answer

Answer: c [Reason:] Moderate level of pH of electrolyte used in ECM range between 4 – 10.

10. What must be the working voltage in Electrochemical machining?
a) 10 V
b) 20 V
c) 30 V
d) 40 V

View Answer

Answer: b [Reason:] The electrolytes in ECM employ a working voltage up to 20 V.

11. Surface roughness depend on which of the following quantities?
a) Crystallographic irregularities
b) Alloy composition
c) Distribution of current density
d) All of the mentioned

View Answer

Answer: d [Reason:] Surface roughness of machined surface in ECM depend on crystallographic irregularities, alloy composition, current density distribution, dislocations and grain boundaries.

12. For a better surface finish, which type of current distribution is required?
a) Even
b) Uneven
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: a [Reason:] More even distribution of the current density leads to a better surface finish.

13. Between which values does the frontal gap’s surface roughness vary?
a) 0.02 to 0.13 µm
b) 0.30 to 1.90 µm
c) 1.93 to 2.64 µm
d) 2.73 to 4.26 µm

View Answer

Answer: b [Reason:] Surface roughness varies between 0.30 to 1.9 µm for frontal gap area.

14. Between which values does the side gap’s surface roughness vary?
a) >1 µm
b) >3 µm
c) >5 µm
d) >7 µm

View Answer

Answer: c [Reason:] Surface roughness value is 5 µm or more for side gap areas.

15. In Electrochemical machining, larger grain size causes which type of finish?
a) Smoother
b) Rougher
c) Finer
d) All of the mentioned

View Answer

Answer: b [Reason:] In ECM, larger grains cause rougher finish than finer grains.