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Machining Processes MCQ Set 1

1. In advanced machining processes, what is the full form of ECJD?
a) Electrochemical Jet Dimensioning
b) Electrochemical Jet Drilling
c) Electrical Jet Drilling
d) Electrical Jet Dimensioning

View Answer

Answer: b [Reason:] In advanced machining processes, full form of ECJD is Electrochemical Jet Drilling.

2. What is the value of diameter-to-depth ratio obtained using ECJD process?
a) 1:10
b) 2:25
c) 1:12
d) 1:100

View Answer

Answer: c [Reason:] Electrochemical jet drilling is the process used for producing fine holes, having diameter to depth ratio of 1:12.

3. Compared to the diameter to depth ratio of ES drilling, how is ECJD’s ratio?
a) Lower
b) Higher
c) Same as ES
d) None of the mentioned

View Answer

Answer: a [Reason:] ES drilling has a diameter to depth ratio of 1:100, while ECJD has a ratio of 1:12.

4. How is the material removed in Electrochemical jet drilling process?
a) Using Platinum wire
b) Using Ti coated electrode
c) By spraying electrolyte
d) Using glass nozzle

View Answer

Answer: c [Reason:] Material is removed by spraying electrolyte through the cathode, in Electrochemical jet drilling.

5. What is the material removal mechanism used in Electrochemical jet drilling?
a) Abrasion
b) Dissolution
c) Vaporization
d) Erosion

View Answer

Answer: b [Reason:] Electrochemical dissolution is the means of material removal in Electrochemical jet drilling.

6. What are the values of voltages used in Electrochemical jet drilling process?
a) 100 to 200 V
b) 200 to 400 V
c) 400 to 800 V
d) 800 to 1600 V

View Answer

Answer: c [Reason:] The optimum range of voltages used in Electrochemical jet drilling are between 400 to 800 V.

7. The lower limit of the hole size in ECJD, is determined by which of the following factors?
a) Smallest hole
b) Pressure required
c) Amount of overcut
d) All of the mentioned

View Answer

Answer: d [Reason:] The lower limit of hole size depend on smallest hole that can be drilled in cathodic nozzle, pressure required for pumping electrolyte and the overcut amount.

8. State whether following statement is true or false regarding ECJD.
“In ECJD, diameter of hole produced, depend up on the throwing power of electrolyte.”
a) True
b) False

View Answer

Answer: a [Reason:] Diameter of the hole produced, depend up on the throwing power of electrolyte.

9. Compared to the diameter of the electrolyte jet, how are the produced hole diameters?
a) 2 times
b) 3 times
c) 4 times
d) 5 times

View Answer

Answer: c [Reason:] In ECJD, the holes produced are nearly 4 times that of the electrolyte jet diameter used in the process.

10. What is the value of the ratio of hole diameter to capillary diameter in ECJD?
a) 2
b) 4
c) 6
d) 8

View Answer

Answer: a [Reason:] Generally, ratio of hole diameter to capillary diameter in ECJD is 2.

11. What are the values of tapers produced in Electrochemical jet drilling process?
a) 1 to 2 included angles
b) 5 to 10 included angles
c) 10 to 15 included angles
d) 20 to 30 included angles

View Answer

Answer: b [Reason:] In Electrochemical jet drilling tapers produced are about 5 to 10 included angles.

12. State whether following statement is true or false regarding ECJD?
“In ECJD, there is no need of room for exit of electrolyte.”
a) True
b) False

View Answer

Answer: b [Reason:] In ECJD, enough room is required for the exit of electrolyte, preferably in the form of spray.

13. How much part of tool needs to be in contact with work piece for removal of material?
a) Quarter
b) Half
c) Full
d) No contact

View Answer

Answer: d [Reason:] As this is an electrochemical dissolution process, electrodes should not be in contact in order to avoid sparking.

Machining Processes MCQ Set 2

1. What is the full form of ECS in the advanced machining processes?
a) Electro chemical superfinishing
b) Electro chemical scribing
c) Electron cluster scribing
d) Electron cluster superfinishing

View Answer

Answer: a [Reason:] The full form of ECS in the advanced machining processes is Electro chemical superfinishing.

2. Which of the mechanisms combine to form this hybrid process of ECS?
a) Electro chemical dissolution
b) Mechanical scrubbing
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Electro chemical dissolution and mechanical scrubbing combined in the hybrid process of ECS.

3. How much amount of burr is produced in the process of ECS?
a) 10 %
b) 20 %
c) 50 %
d) No burr produced

View Answer

Answer: d [Reason:] Burr free components are produced in the process of Electro chemical superfinishing due to electro chemical dissolution.

4. MRR are reduced by how much amount in the presence of the oxide film?
a) 10 %
b) 30 %
c) 50 %
d) 70 %

View Answer

Answer: c [Reason:] Material removal rates are reduced by 50 % in the presence of the film in Electro chemical superfinishing.

5. What are the tolerance values obtained in the ECS process?
a) ± 0.003 mm
b) ± 0.013 mm
c) ± 0.023 mm
d) ± 0.033 mm

View Answer

Answer: b [Reason:] The tolerance values obtained in the Electro chemical superfinishing process are about ± 0.013 mm on the diameter.

6. What are the values of roundness and straightness obtained from machining using ECS?
a) 0.001 mm
b) 0.003 mm
c) 0.007 mm
d) 0.013 mm

View Answer

Answer: c [Reason:] The values of roundness and straightness obtained from machining by Electro chemical superfinishing process is about 0.007 mm.

7. Which of the following are the process variables related to ECS?
a) Gap voltage
b) Electrolyte type
c) Concentration
d) All of the mentioned

View Answer

Answer: d [Reason:] Gap voltage, electrolyte type, concentration and temperature are some of the variable related to Electro chemical superfinishing.

8. Which of the following affect the process performance of Mechanical scrubbing?
a) Stone pressure
b) Oscillating frequency
c) Amplitude
d) All of the mentioned

View Answer

Answer: d [Reason:] Stone pressure, oscillating frequency and amplitude affect the mechanical scrubbing in the process of Electro chemical superfinishing.

9. High electro chemical dissolutions occur at which type of current densities?
a) Very Low
b) Low
c) Moderate
d) High

View Answer

Answer: d [Reason:] High electro chemical dissolutions occur at high current densities in the process of Electro chemical superfinishing.

10. Rise in different parameters related to the MS and ECD lead to ______ material removal rates.
a) Increase in
b) Decrease in
c) Normal
d) All of the mentioned

View Answer

Answer: a [Reason:] A rise in the scrubbing speed, voltage, and duty cycle would lead to an increase in MRR.

Machining Processes MCQ Set 3

1. What is the full form of EBM in the advanced machining processes?
a) Electro blast manufacturing
b) Electron beam machining
c) Electron beam manufacturing
d) Electron blast manufacturing

View Answer

Answer: b [Reason:] The full form of EBM is Electron beam machining in the advanced machining processes.

2. The prototype of the machine used in EBM process was first introduced in which year?
a) 1924
b) 1943
c) 1947
d) 1956

View Answer

Answer: c [Reason:] Steigerwald was the scientist who designed a prototype machine of electron beam machining in 1947.

3. When did the Electron beam machining come into the machining industry?
a) 1920s
b) 1930s
c) 1950s
d) 1960s

View Answer

Answer: d [Reason:] The Electron beam machining was introduced to the machining industry in the early 1960s.

4. Which of the following are the applications of EBM process?
a) Drilling
b) Cutting
c) Engraving
d) All of the mentioned

View Answer

Answer: d [Reason:] Drilling small holes, cutting, engraving, and heat treatment are some of modern applications of Electron beam machining.

5. The tungsten filament cathode is heated to what temperatures in EBM?
a) 1000 to 1500 ᵒC
b) 1500 to 2000 ᵒC
c) 2500 to 3000 ᵒC
d) 3500 to 5000 ᵒC

View Answer

Answer: c [Reason:] The tungsten filament cathode is heated to 2500 to 3000 ᵒC in Electron beam machining.

6. What are the values of currents used in EBM process?
a) 1 and 20 mA
b) 20 and 100 mA
c) 100 and 200 mA
d) 200 and 400 mA

View Answer

Answer: b [Reason:] The values of the currents used in the Electron beam machining process are between 20 and 100 mA.

7. What are the values of current densities used in the process of EBM?
a) 5 and 15 A/cm2
b) 15 and 20 A/cm2
c) 20 and 30 A/cm2
d) 40 and 60 A/cm2

View Answer

Answer: a [Reason:] The values of the current densities used in EBM lie between 5 and 15 A/cm2.

8. Emission current depends up on which of the following factors?
a) Cathode material
b) Temperature
c) Voltage supply
d) All of the mentioned

View Answer

Answer: d [Reason:] Emission current depends on the cathode material, temperature, and the high voltage in the process of Electron beam machining.

9. What are the values of voltages used in the EBM process?
a) 10 V
b) 50 V
c) 150 V
d) 200 V

View Answer

Answer: c [Reason:] The values of voltages used in the process of electron beam machining is about 150 V.

10. Which of the following lenses are used for refocussing the electrons in EBM process?
a) Magnetic lens
b) Electronic lens
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Magnetic and electronic lenses are used to refocus the electrons in EBM process.

11. What are the values of velocity maintained in the EBM process?
a) 118 x 103 m/s
b) 228 x 103 m/s
c) 338 x 103 m/s
d) 448 x 103 m/s

View Answer

Answer: b [Reason:] The value of the velocity used in the process of electron beam machining is about 228 x 103 m/s.

12. What are the values of power densities used in the EBM process?
a) 0.05 MW/mm2
b) 0.55 MW/mm2
c) 1.55 MW/mm2
d) 2.55 MW/mm2

View Answer

Answer: c [Reason:] The value of the power densities used in the process of electron beam machining are about 1.55 MW/mm2.

13. What is the frequency of the pulse of electrons used in EBM process?
a) 10 Hz
b) 102 Hz
c) 103 Hz
d) 104 Hz

View Answer

Answer: d [Reason:] A pulsed electron beam at 104 Hz reduces the temperature of the work piece outside the region being machined.

14. What are the values of material removal rates in EBM process?
a) 1 mm3/min
b) 10 mm3/min
c) 100 mm3/min
d) 1000 mm3/min

View Answer

Answer: b [Reason:] The values of the material removal rates in the process of electron beam machining are about 10 mm3/min.

15. What are the values of the cavity diameters that are obtained in EBM?
a) 15 to 20 µm
b) 20 to 25 µm
c) 30 to 35 µm
d) 35 to 40 µm

View Answer

Answer: d [Reason:] The values of the cavity diameters range from 35 to 40 µm.

Machining Processes MCQ Set 4

1. In advanced machining processes, what is the full form of EP?
a) Electro plating
b) Electro polishing
c) Electron pocketing
d) Electrical punching

View Answer

Answer: b [Reason:] Full form of EP is Electro-polishing in advanced machining processes.

2. When was the process Electro polishing introduced to the advanced machining processes?
a) 1918
b) 1922
c) 1935
d) 1943

View Answer

Answer: c [Reason:] Electropolishing was introduced to world in the year 1935, when Cu and Zn were successfully electropolished by Germans.

3. How is the material removed in Electropolishing process?
a) Anodic dissolution
b) Cathodic dissolution
c) Chemical corrosion
d) Mechanical erosion

View Answer

Answer: a [Reason:] Material in Electropolishing is removed by anodic dissolution process.

4. State whether following statement is true or false regarding EP process.
“Electropolishing is same as electro plating.”
a) True
b) False

View Answer

Answer: b [Reason:] Electropolishing is the opposite of electroplating.

5. Of the following terminals, part to be finished acts as which terminal in EP process?
a) Anode
b) Cathode
c) Neutral
d) None of the mentioned

View Answer

Answer: a [Reason:] As this process is opposite to that of Electro plating, part to be finished is the anode in EP.

6. Which of the following come under the components of EP process?
a) Electrolyte solution
b) Dc power supply
c) Work piece
d) All of the mentioned

View Answer

Answer: d [Reason:] The EP process components include DC power supply, electrolyte, electrically charged terminals, of which, one of them is work piece.

7. Electrolytic solution is a mixture of which of the following?
a) Insoluble salts
b) Several acids
c) All of them mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Electrolytic solution is a mixture of several acids and insoluble salts.

8. What amount of current density can be used for Electropolishing to take place?
a) Very low
b) Low
c) Optimum
d) Very high

View Answer

Answer: b [Reason:] Limiting amount of current should be used in EP process for anodic dissolution.

9. Which of the following takes place if the current density used is relatively high?
a) Smoothing
b) Finishing
c) Oxygen evolution
d) All of the mentioned

View Answer

Answer: c [Reason:] If the current level increases beyond the limiting value, pitting takes place due to gas evolution.

10. More anodic dissolution takes place at which part of the surface of the work piece?
a) Peaks
b) Valleys
c) Troughs
d) None of the mentioned

View Answer

Answer: a [Reason:] Anodic dissolution is high at peaks when compared to valleys on the surface of the work pieces.

11. State whether following statement is true or false about EP process.
“In EP, produced surface possess true crystalline structure without distortion.”
a) True
b) False

View Answer

Answer: a [Reason:] In Electropolishing, the produced surface possess true crystalline structure without distortion, unlike that of cold working as in mechanical finishing.

12. Surfaces produced in Electropolishing process possess which of the qualities?
a) Bright
b) Clean
c) Microscopically smooth
d) All of the mentioned

View Answer

Answer: d [Reason:] Surfaces produced in EP becomes clean, bright and microscopically smooth.

13. How much amount of properties of bulk material, are possessed by the finished part in EP?
a) Negligible amount
b) Only some properties
c) All properties
d) None of the mentioned

View Answer

Answer: c [Reason:] The part machined using EP process, possess true properties of the bulk material.

14. State whether following statement is true or false regarding EP.
“Fine direction lines are left in EP, like that of abrasive polishing.”
a) True
b) False

View Answer

Answer: b [Reason:] Unlike that of abrasive polishing, fine direction lines are not produced.

Machining Processes MCQ Set 5

1. In advanced machining processes, what is the full form of ES drilling?
a) Electro stream
b) Electrical shaped
c) Electron shaped
d) Electric shock

View Answer

Answer: a [Reason:] In advanced machining processes, full form of ES drilling is Electrostream drilling.

2. This Electrostream drilling is used when we cannot drill which of the following type of holes?
a) Too deep holes by EDM
b) Small holes by STEM
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] ES drilling is used to drill finer holes which are too deep to be produced by EDM and too small to be drilled by STEM.

3. What is the value of diameter of glass nozzle used in Electrostream drilling?
a) 0.01 – 0.02 mm
b) 0.025 – 0.5 mm
c) 0.5 – 0.75 mm
d) 0.75 – 1.25 mm

View Answer

Answer: b [Reason:] Electrostream drilling uses a gas nozzle, whose diameter ranges between 0.025 – 0.5 mm.

4. Compared to the required diameter of the hole, how is the nozzle diameter?
a) Smaller
b) Larger
c) Same as required
d) All of the mentioned

View Answer

Answer: a [Reason:] The diameter of nozzle used is smaller than the hole size required to be drilled in work piece.

5. Which of the following acts as the cathodic tool in ES drilling?
a) Titanium base
b) Platinum wire
c) Glass nozzle
d) Work piece

View Answer

Answer: b [Reason:] Unlike the case of STEM process, which uses coated Ti tube as cathode, ES drilling used platinum wire as cathode electrode.

6. What is the concentration of electrolytes that are commonly used in ES drilling?
a) 1 to 10wt %
b) 12 to 20wt %
c) 23 to 30wt %
d) 34 to 50wt %

View Answer

Answer: b [Reason:] Commonly used electrolytes have a concentration between 12 to 20wt %.

7. State whether following statement is true or false regarding ES drilling.
“In ES drilling, hydrochloric acid is used for machining aluminium and its alloys.”
a) True
b) False

View Answer

Answer: a [Reason:] Hydrochloric acids are used for machining Al and its alloys and sulphuric acid is recommended for other metals.

8. Which of the following are the metals, which can be machined using sulphuric acid?
a) Carbon steels
b) Haste alloy
c) Inconel
d) All of the mentioned

View Answer

Answer: d [Reason:] Haste alloy, Rene alloy, Inconel, carbon and stainless steels are the materials machined using sulphuric acid.

9. What are the values of electrolyte pressure recommended for ES drilling?
a) 50 – 100 kPa
b) 100 – 250 kPa
c) 275 – 400 kPa
d) 500 – 750 kPa

View Answer

Answer: c [Reason:] Electrolyte pressure values must range between 275 – 400 kPa for ES drilling to take place.

10. Which of the following parameters must be carefully monitored for satisfactory machining?
a) Acid temperature
b) Pressure
c) Concentration
d) All of the mentioned

View Answer

Answer: d [Reason:] Acid temperature, pressure, concentration and feed rate are to be carefully monitored for satisfactory machining.

11. What are the values of voltages used in ES drilling process?
a) 10 to 40 V
b) 40 to 70 V
c) 70 to 150 V
d) 150 to 300 V

View Answer

Answer: c [Reason:] Voltage values used in ES drilling, range between 70 to 150 V.

12. What are the values of feed rates used in ES drilling process?
a) 0.01 to 0.5 mm/min
b) 0.75 to 2.5 mm/min
c) 3 to 4.5 mm/min
d) 5 to 7.5 mm/min

View Answer

Answer: b [Reason:] Feed rate values used in ES drilling, range between 0.75 to 2.5 mm/min.

13. Higher material removal rates are associated with _____ feed rates and _____ tool diameters.
a) Larger, smaller
b) Smaller, larger
c) Smaller, smaller
d) Larger, larger

View Answer

Answer: d [Reason:] Rates of material removal are high, when feed rates are high and larger tool diameters.

14. What are the normal hole depth tolerance values in ES drilling?
a) ± 0.03 mm
b) ± 0.05 mm
c) ± 0.07 mm
d) ± 0.09 mm

View Answer

Answer: b [Reason:] The normal hole depth tolerances obtained in ES drilling, range between ± 0.05 mm.

15. How many holes can be drilled simultaneously using ES drilling process?
a) One hole
b) Two holes
c) Three holes
d) Multiple holes

View Answer

Answer: d [Reason:] Depending upon the size of diameters, multiple holes can be drilled using ES drilling.