Machining Processes MCQ Set 1
1. In advanced machining processes, what is the full form of EDM?
a) Electro discharge Machining
b) Electro discharge Manufacturing
c) Electrical dimensioning Machining
d) Electrode dimensions Manufacturing
Answer
Answer: a [Reason:] Full form of EDM in advanced machining processes is, Electrodischarge machining.
2. The evolution of wire EDM took place in which part of history?
a) 1940s
b) 1950s
c) 1960s
d) 1970s
Answer
Answer: d [Reason:] Evolution of wire EDM in 1970s was due to powerful generators, new wire electrodes, improved machining intelligence and better flushing.
3. Machining speeds have gone up to how many times after the invention of EDM?
a) Ten
b) Twenty
c) Thirty
d) Fifty
Answer
Answer: b [Reason:] Machining speeds have gone up to 20 times after the invention of EDM.
4. By using EDM, how much percentage of machining costs can be reduced?
a) 10 %
b) 20 %
c) 30 %
d) 50 %
Answer
Answer: c [Reason:] EDM decreased the machined cost at least by 30 %.
5. After invention of EDM, surface finish have improved by how much factor?
a) 10
b) 15
c) 20
d) 25
Answer
Answer: b [Reason:] Surface finish have been improved by a factor of 15 after the invention of EDM.
6. Cavities with, which of the following factors can be produced using Electro discharge machining?
a) Thin walls
b) Fine features
c) All of the mentioned
d) None of the mentioned
Answer
Answer: c [Reason:] Cavities with thin walls and fine features can be machined using EDM.
7. Which of the following geometries can be machined using EDM?
a) Simple
b) Complex
c) Difficult to cut
d) All of the mentioned
Answer
Answer: d [Reason:] Electrodischarge machining can be used for simple as well as complex geometries.
8. State whether following statement is true or false regarding EDM.
“In EDM, process is affected by hardness of material.”
a) True
b) False
Answer
Answer: b [Reason:] EDM process is not affected by the hardness of material.
9. How much amount of burr is produced in this process?
a) 10 %
b) 40 %
c) 70 %
d) No burr
Answer
Answer: d [Reason:] Electro discharge machining is a burr free process.
10. Which of the following mechanisms is used for material removal?
a) Electro discharge erosion
b) Magnetic abrasion
c) Electro chemical dissolution
d) Mechanical erosion
Answer
Answer: a [Reason:] Material is removed by electro discharge erosion (EDE) in EDM.
Machining Processes MCQ Set 2
1. 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
Answer: a [Reason:] The full form of ECB is Electro chemical buffing in the advanced machining processes.
2. 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
Answer: b [Reason:] Electro chemical buffing process is a faster machining process when compared to the conventional mechanical buffing.
3. Which of the following electrolytes are used ECB process?
a) Sodium chloride solution
b) Sodium nitrate solution
c) All of the mentioned
d) None of the mentioned
Answer
Answer: c [Reason:] Sodium chloride and sodium nitrate are the electrolytes that are used for machining purpose in the process of Electro chemical buffing.
4. 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
Answer: d [Reason:] The concentration of sodium chloride solution used for machining in ECB is about 100 – 500 g/L.
5. 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
Answer: b [Reason:] The current densities used in the process of ECB range between 0.1 and 7 A/cm2.
6. 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
Answer: b [Reason:] The value of the buffing speed in Electro chemical buffing is about 1 – 6 m/s.
7. 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
Answer: c [Reason:] The values of contact pressure used in the ECB process are between 100 and 600 g.
8. 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
Answer: a [Reason:] The values of electrolyte flow rates used in ECB process range between 1 – 10 L/min.
9. 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
Answer: d [Reason:] The factors that control the polishing speed are current density, electrolyte time, work piece material.
10. Which of the following electrolytes can be used for high speed polishing?
a) Sodium chloride
b) Sodium nitrate
c) All of the mentioned
d) None of the mentioned
Answer
Answer: a [Reason:] Sodium chloride electrolyte can be used for high speed polishing in Electro chemical buffing process.
Machining Processes MCQ Set 3
1. In advanced machining processes, full form of ECDB is _____
a) Electrochemical Drill buffing
b) Electrochemical Dimension Breaking
c) Electrochemical Deburring
d) Electrochemical Dimensioning
Answer
Answer: c [Reason:] In advanced machining processes, full form of ECDB is Electrochemical Deburring.
2. Which of the following processes can be used for deburring?
a) Water blasting
b) Abrasive flow machining
c) Electrochemical deburring
d) All of the mentioned
Answer
Answer: d [Reason:] Different methods used for deburring include vibratory and barrel finishing, tumbling, water blasting, Abrasive flow machining, Electrochemical deburring and many more.
3. Of the following electrodes, on which one the process of deburring takes place?
a) Cathode
b) Anode
c) All of the mentioned
d) None of the mentioned
Answer
Answer: c [Reason:] Anode is the electrode, on which, the process of deburring is done.
4. Burrs are removed at which amount of current densities below?
a) Very low
b) Low
c) High
d) Medium
Answer
Answer: c [Reason:] High current densities are required to remove the burrs from the work pieces.
5. After deburring is done, which of the following is formed?
a) Flat surfaces
b) Controlled radius
c) Sharp edges
d) All of the mentioned
Answer
Answer: b [Reason:] Dimensions of the part are changes by the removal of burrs leaving a controlled radius.
6. To which components mentioned below, ECDM can be applied?
a) Spline shafts
b) Milled components
c) Drilled holes
d) All of the mentioned
Answer
Answer: d [Reason:] ECDB can be applied to gears, spline shafts, milled components, drilled holes, and punched blanks.
7. What are the values of deburring speeds used in ECDB process?
a) 100 to 200 mm/min
b) 200 to 400 mm/min
c) 400 to 500 mm/min
d) 500 to 700 mm/min
Answer
Answer: c [Reason:] Values of speeds of deburring, range between 400 to 500 mm/min.
8. What are the normal cycle times for deburring process using ECDB?
a) 10 to 20 s
b) 30 to 45 s
c) 50 to 70 s
d) 80 to 100 s
Answer
Answer: b [Reason:] The normal cycle times are between 30 to 45 s after which, spindle is retracted and part is removed.
9. What is the value of burr height that can be removed using ECDB process?
a) 0.1 mm
b) 0.3 mm
c) 0.5 mm
d) 0.7 mm
Answer
Answer: c [Reason:] Burr height of around 0.5 mm can be removed using ECDB process.
10. Burr is removed to a radius of _____ in ECDB process.
a) 0.01 to 0.04 mm
b) 0.05 to 0.20 mm
c) 0.25 to 0.40 mm
d) 0.50 to 0.75 mm
Answer
Answer: b [Reason:] Burr of height 0.5 mm to a radius of 0.05 to 0.2 mm can be removed using ECDB.
11. What is the value of surface roughness obtained in Electrochemical deburring process?
a) 0.1 to 1 µm
b) 1 to 2 µm
c) 2 to 4 µm
d) 5 to 8 µm
Answer
Answer: c [Reason:] Surface roughness obtained in ECDB process is about 2 to 4 µm.
Machining Processes MCQ Set 4
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
Answer: b [Reason:] 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
Answer: c [Reason:] 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
Answer: d [Reason:] 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
Answer: c [Reason:] 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
Answer: b [Reason:] 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
Answer: c [Reason:] 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
Answer: a [Reason:] 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
Answer: c [Reason:] 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
Answer: c [Reason:] The values of current in Electro chemical grinding range from 50 to 300 A.
10. State whether 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
Answer: b [Reason:] Abrasive particles continuously remove the material products from the working area in Electro chemical grinding.
Machining Processes MCQ Set 5
1. 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
Answer: a [Reason:] The full form of ECH in the advanced machining processes is Electro chemical honing.
2. Which of the following mechanisms are used in the hybrid machining of ECH?
a) Electro chemical dissolution
b) Mechanical abrasion
c) All of the mentioned
d) None of the mentioned
Answer
Answer: c [Reason:] MA and ECD are used in material removal of the hybrid process of ECH.
3. 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
Answer: b [Reason:] Electro chemical honing has higher material removal rates than conventional honing and the internal cylindrical grinding processes.
4. Majority of the material is removed in which phase of ECH?
a) Electro chemical dissolution
b) Mechanical abrasion
c) All of the mentioned
d) None of the mentioned
Answer
Answer: a [Reason:] Majority of the material in Electro chemical honing is removed in electro chemical dissolution phase.
5. Which of the following electrolytes is used for ECH process?
a) Sodium chloride
b) Sodium nitrate
c) Hydrochloric acid
d) Sulphuric acid
Answer
Answer: b [Reason:] Sodium nitrate (240 g/L) is mostly used than Sodium chloride (120 g/L) and other acid electrolytes in Electro chemical honing.
6. What is the value of electrolytic temperature maintained in ECH?
a) 18 ᵒC
b) 28 ᵒC
c) 38 ᵒC
d) 48 ᵒC
Answer
Answer: c [Reason:] The value of the temperature of the electrolytic solution that is used in Electro chemical honing process is about 38 ᵒC.
7. 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
Answer: d [Reason:] The value of the pressure of the electrolytic solution maintained in Electro chemical process is about 1000 kPa.
8. 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
Answer: b [Reason:] The rate of the electrolytic solution used in Electro chemical honing process is about 95 L/min.
9. 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
Answer: c [Reason:] The voltage values used in ECH range from 6 to 30 V.
10. 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
Answer: d [Reason:] The current density values that are used in the process of Electro chemical honing are about 465 A/cm2.
