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Machining Processes MCQ Set 1

1. For economical and high quality Electropolishing, which of the following materials are used?
a) Cold rolled metals
b) Hot flat metals
c) Hot plastics
d) All of the mentioned

View Answer

Answer: a [Reason:] Cold rolled metals are the most important materials for economical and high quality polishing.

2. State whether following statement is true or false about applications of EP.
“In EP, cast items do not maintain the texture of sand mold.”
a) True
b) False

View Answer

Answer: b [Reason:] Cast items usually maintain the texture of sand mold since they have coarse grains and include alloying elements.

3. Which of the following cannot be removed by using Electropolishing process?
a) Scales
b) Distortion
c) Coarse texture
d) Burrs

View Answer

Answer: c [Reason:] Coarse texture cannot be removed using Electropolishing as they produce rough surfaces.

4. Electropolishing prepares surfaces for which of the following processes?
a) Electron Beam machining
b) Electro plating
c) Laser beam machining
d) Magnetic Abrasive machining

View Answer

Answer: b [Reason:] EP prepares surfaces for electroplating, which creates an opportunity for best adherence.

5. For which of the following components, polishing can be done using EP?
a) Electrical conduits
b) Outlet boxes
c) Medical equipment
d) All of the mentioned

View Answer

Answer: d [Reason:] Polishing light fixtures of electrical conduits, outlet boxes, and medical, surgical, and food processing equipment.

6. State whether following statement is true or false regarding the applications of EP.
“Using Electropolishing, deburring and breaking sharp edges can be done.”
a) True
b) False

View Answer

Answer: a [Reason:] Deburring and breaking sharp edges obtained from hand filing, grinding and honing of tools.

7. Electropolishing removes scales and distortions that are produces by which of the processes below?
a) Annealing
b) Nitriding
c) Carburizing
d) All of the mentioned

View Answer

Answer: d [Reason:] Scales and distortions produced by annealing, carburizing, nitriding, welding and soldering can be removed using EP.

8. State whether following statement is true or false about applications of EP.
“In EP, removal of hardness and stressed surface layers, reduces life of parts.”
a) True
b) False

View Answer

Answer: b [Reason:] Removal of hardness and stressed surface layers improves the surface life of part.

9. Polishing of how many parts can be done using Electropolishing?
a) One part
b) Two parts
c) Multiple parts
d) None of the mentioned

View Answer

Answer: c [Reason:] Multiple parts can be polished simultaneously using EP, depending upon the size of parts.

10. Electropolishing cannot cover up which type of defects?
a) Burrs on surfaces
b) Scales and distortions
c) Non-metallic inclusions
d) Metallographic examination

View Answer

Answer: c [Reason:] Seams and non-metallic inclusions are some defects which cannot be covered up using EP.

11. Which of the following is a limitation of EP process?
a) Rough scratches removal
b) Scales removal
c) Distortions removal
d) Burr removal

View Answer

Answer: a [Reason:] In EP, rough scratches cannot be removed even by considerable amount of process.

12. Metals containing which of the following chemicals will be troublesome in EP process?
a) Silicon
b) Lead
c) Sulphur
d) All of them mentioned

View Answer

Answer: d [Reason:] All the elements mentioned above, if present in metals, will be troublesome in EP process.

13. State whether following statement is true or false regarding the limitations of EP?
“In EP, base metal condition does not affect the process.”
a) True
b) False

View Answer

Answer: b [Reason:] Base metal condition affects the process of EP.

14. Which of the following defects lead to poor electropolishing of the surfaces?
a) Improper annealing
b) Non-metallic inclusions
c) Over pickling
d) All of the mentioned

View Answer

Answer: d [Reason:] Non-metallic inclusions, over pickling, large grain size, direction roll marks, improper cold reduction leads to poor electro polishing.

15. Electropolishing is more suited for, removal of which of the following defects?
a) Small scratches
b) Imperfections
c) Smoothing
d) All of the mentioned

View Answer

Answer: d [Reason:] Small scratches and imperfections can be easily removed, when compared to that of rough scratches.

Machining Processes MCQ Set 2

1. Of the following material removal mechanisms, material is removed by which one in EP?
a) Electrode dissolution
b) Corrosion
c) Abrasion
d) Erosion

View Answer

Answer: a [Reason:] Anodic dissolution takes place in Electropolishing process.

2. Which of the following come under the process parameters of the Electropolishing?
a) Work piece material and condition
b) Current density
c) Applied voltage
d) All of the mentioned

View Answer

Answer: d [Reason:] The process parameters of Electropolishing include current density, applied voltage, acid type, temperature original surface roughness, work piece condition and material.

3. Current density of the EP process generally varies between which of the following values?
a) 0.0001 – 0.001 A/cm2
b) 0.005 – 1.8 A/cm2
c) 1.9 – 2.532 A/cm2
d) 3.523 – 4.23 A/cm2

View Answer

Answer: b [Reason:] Generally current density value used in EP process vary between 0.005 – 1.8 A/cm2.

4. Which of the following are the work piece materials that can be machined using Electropolishing?
a) Carbon steel
b) Alpha brass
c) Phosphor bronze
d) All of the mentioned

View Answer

Answer: d [Reason:] Different work piece materials that can be machined using EP are carbon steels, stainless steels, copper, alpha brass, nickel, phosphor bronze, aluminium, magnesium etc.

5. Which of the following electrolyte, can be used commonly for stainless steel, Cu, Ni and Mg?
a) HCLO4
b) H2PO4
c) H2SO4
d) HNO3

View Answer

Answer: b [Reason:] H2PO4 is a common electrolyte used in the machining of Cu, Ni, Mg.

6. What is the electrolytic solution’s temperature when stainless steel is machined?
a) 50o C
b) 80o C
c) 120o C
d) 150o C

View Answer

Answer: b [Reason:] Temperature of electrolytic solution used for machining stainless steel is 80o C.

7. State whether following statement is true or false regarding process parameters of EP.
“In EP, process parameters have a direct impact on surface quality and productivity of process.”
a) True
b) False

View Answer

Answer: a [Reason:] In Electropolishing, parameters have a direct impact on quality of surface and productivity.

8. For machining of Cu material which of the following can be used as electrolytes?
a) H2PO4
b) H2PO4 and Na2CrO4
c) HCLO4
d) HNO3

View Answer

Answer: a [Reason:] For Cu material electrolyte used in EP process is H2PO4.

9. Of the following types of voltage, which one best suites EP process?
a) Randomly Fluctuating
b) Constant
c) Periodically fluctuating
d) None of the mentioned

View Answer

Answer: b [Reason:] For the machining to take place in Electropolishing process, voltage should be correct and constant.

10. State whether following statement is true or false regarding process parameters of EP.
“In EP, high current densities are used for anodic dissolution.”
a) True
b) False

View Answer

Answer: b [Reason:] In Electropolishing, limited current densities are used for anodic dissolution.

Machining Processes MCQ Set 3

1. What are the dimensions that can machined on IBM?
a) 0.1 to 1 nm
b) 1 to 10 nm
c) 10 to 100 nm
d) 100 to 1000 nm

View Answer

Answer: c [Reason:] Small dimensions as 10 to 100 nm can also be machined on Ion beam machining.

2. The slope of the side walls depends on which of the following factors?
a) Voltage supply
b) Angle of incidence
c) Flux
d) Current density

View Answer

Answer: b [Reason:] The slope of the sidewalls of the surface and its surface finish depend on the angle of incidence.

3. What are the accuracy levels that are obtained by using IBM?
a) ± 1.0%
b) ± 2.0%
c) ± 3.0%
d) ± 4.0%

View Answer

Answer: a [Reason:] The accuracy levels that are obtained when machined the work piece using IBM is about ± 1.0 %.

4. What are the values of repeatability obtained in Ion beam machining?
a) ± 1.0%
b) ± 2.0%
c) ± 3.0%
d) ± 4.0%

View Answer

Answer: a [Reason:] A repeatability of about ± 1 % are obtained while machining the work piece using Ion beam machining process.

5. Surface texturing produces a cone-and-ridge like configuration on the order of which size?
a) 0.5 µm
b) 1 µm
c) 1.5 µm
d) 2 µm

View Answer

Answer: b [Reason:] Surface texturing produces a cone-and-ridge-like configuration on the order of 1 µm in size in Ion beam machining.

6. What is the value of surface finish obtained by using Ion beam machining?
a) <1 µm
b) <3 µm
c) <5 µm
d) <7 µm

View Answer

Answer: a [Reason:] The smoothness of the surface finish obtained in Ion beam machining is less than 1 µm.

7. Which of the following are the applications of IBM?
a) Smoothing laser mirrors
b) Polishing surfaces
c) Shaping surface
d) All of the mentioned

View Answer

Answer: d [Reason:] Smoothing of laser mirrors, polishing and shaping of optical surfaces are some of the applications of Ion beam machining.

8. State whether following statement is true or false regarding the applications of IBM.
“In IBM, thickness can be reduced which affects the surface finish.”
a) True
b) False

View Answer

Answer: b [Reason:] Reduction of thickness of thin films can be done without affecting the surface finish.

9. What are the thickness values of silicon samples that can be thinned?
a) 1 to 5 µm
b) 5 to 10 µm
c) 10 to 15 µm
d) 15 to 20 µm

View Answer

Answer: c [Reason:] Thickness ranging from 10 to 15 µm can be thinned using IBM.

10. Which of the following materials can be textured using the IBM process?
a) Copper
b) Nickel
c) Stainless steel
d) All of the mentioned

View Answer

Answer: d [Reason:] Materials such as Copper, stainless steel, nickel, silver and gold can be used for producing textured cones using IBM.

11. How much amount of energies are required for removal of oxide layers?
a) Small
b) Larger
c) Moderate
d) All of the mentioned

View Answer

Answer: b [Reason:] Higher energies are needed for the removal of layer of oxides on the surfaces using Ion Beam machining.

Machining Processes MCQ Set 4

1. In the existing advanced machining processes, what is the full form of IJM?
a) Ice Jet Manufacturing
b) Ink Jet Manufacturing
c) Ice Jet Machining
d) Ink Jet Machining

View Answer

Answer: c [Reason:] Full form of IJM is Ice jet machining in advanced machining processes.

2. In Ice jet machining, the abrasive particles used for material removal are replaced by which of the following?
a) Silica particles
b) Ice particles
c) Fluids
d) Colloidal solutions

View Answer

Answer: b [Reason:] In Ice jet machining, the abrasive particles are replaced by ice particles.

3. When compared to Abrasive water jet machining, how are the material removal rates in Ice jet machining?
a) Very low
b) Low
c) High
d) Remains same

View Answer

Answer: b [Reason:] In Ice jet machining, material removal rates are relatively low when compared to AWJM.

4. State whether the following statement is true or false about Ice jet machining.
“Water can be reused in IJM, unlike that of AWJM and WJM.”
a) True
b) False

View Answer

Answer: a [Reason:] Unlike that of AWJM, water can be reused in Ice jet machining.

5. Which of the following are the components of machining system of IJM?
a) High pressure pump
b) Ice particle generator
c) Ultrasonic Atomizer
d) All of the mentioned

View Answer

Answer: d [Reason:] All the components mentioned above are present in the machining system of IJM.

6. Which of the following component will be present just after the cooling coil?
a) High pressure pump
b) Ice particle generator
c) Cutting nozzle
d) Ultrasonic Atomizer

View Answer

Answer: c [Reason:] Prior to nozzle water is cooled by coils that is submerged in liquid nitrogen.

7. Ice particles of size <500 µm are produced by which of the following process?
a) Stream freezing
b) Ice particles supply
c) Normal cooling
d) None of the mentioned

View Answer

Answer: a [Reason:] Ice particles of size <500 µm are produced by using stream freezing.

8. Ice particles of size >500 µm are produced by which of the following process?
a) Stream freezing
b) Ice particles supply
c) Normal cooling
d) None of the mentioned

View Answer

Answer: b [Reason:] Ice particles of size >500 µm are produced by ice particles supply.

9. In Ice jet machining, stand-off distance value varies between which of the following?
a) 1.0 – 2.0 mm
b) 2.0 – 3.0 mm
c) 3.0 – 5.0 mm
d) 5.0 – 10.0 mm

View Answer

Answer: c [Reason:] Value of the stand-off distance ranges between 3.0 – 5.0 mm in IJM.

10. What is the value of diameter of nozzle that is used in Ice jet machining?
a) 0.175 mm
b) 0.425 mm
c) 0.548 mm
d) 0.654 mm

View Answer

Answer: a [Reason:] The value of diameter of nozzle in Ice jet machining is about 0.175 mm.

11. Ultrasonic atomizer used in ice particle generator, produces water droplets at which rate?
a) 0.1 ltr/hr to 1 ltr/hr
b) 2 ltr/hr to 12 ltr/hr
c) 20 ltr/hr to 35 ltr/hr
d) 40 ltr/hr to 65 ltr/hr

View Answer

Answer: b [Reason:] Atomizer produces droplets at the rate 2 ltr/hr to 12 ltr/hr.

12. What are the advantages of Ice jet machining over the other advanced machining processes?
a) Environmentally safe
b) Cost reduction
c) No heat affected zone
d) All of the mentioned

View Answer

Answer: d [Reason:] Advantages of Ice Jet Machining are mentioned above when compared to other processes.

13. Which of the following is a disadvantage of ice jet machining when compared to AWJM?
a) Environmentally safe
b) Cost reduction
c) Low material removal rate
d) No heat affected zone

View Answer

Answer: c [Reason:] When compared to AWJM, IJM has lower material removal rates.

14. Which of the following are the processes and applications by the use of IJM?
a) Ice Deburring process
b) Ice Cutting process
c) Ice Blasting process
d) All of the mentioned

View Answer

Answer: d [Reason:] All the processes mentioned above are done by using IJM.

15. Which of the following industries use Ice jet machining for different applications?
a) Food industry
b) Medical industry
c) Space industry
d) All of the mentioned

View Answer

Answer: d [Reason:] Different type of industries mentioned above use Ice jet machining for wide variety of applications.

Machining Processes MCQ Set 5

1. What is the full form of IBM in the advanced machining processes?
a) Ion Beam Machining
b) Ion Beam Manufacturing
c) Ion Blast Machining
d) Ion Blast Manufacturing

View Answer

Answer: a [Reason:] The full form of IBM is Ion Beam Machining in the advanced machining processes.

2. State whether following statement is true or false regarding IBM.
“In IBM, vacuum chamber is not necessary unlike that of Electron beam machining.”
a) True
b) False

View Answer

Answer: b [Reason:] Ion beam machining also requires a vacuum chamber like that required for Electron beam machining.

3. Which of the following are the components of Ion beam machining?
a) Vacuum chamber
b) Voltage source
c) Tungsten filament cathode
d) All of the mentioned

View Answer

Answer: d [Reason:] Main components of IBM are vacuum chamber, voltage source, tungsten cathode filament, plasma source of argon atoms and lens.

4. How does the ions strike the work piece in machining using IBM?
a) Oblique striking
b) Normal incident striking
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] The ions may strike obliquely or at normal incidence in Ion Beam machining.

5. Number of atoms yielded in oblique cutting is _____ normal incidence.
a) Greater than
b) Lesser than
c) Same as
d) None of the mentioned

View Answer

Answer: a [Reason:] Number of atoms yielded for an incident atom in oblique cutting is greater than normal incidence in IBM.

6. How much amount of energy is required for effective removal of atoms?
a) 1 to 5 eV
b) 5 to 10 eV
c) 10 to 15 eV
d) 15 to 20 eV

View Answer

Answer: b [Reason:] About 5 to 10eV of energy is required for effective removal of atoms.

7. Machining rates in IBM depend on which of the following factors?
a) Work piece material
b) Ions type
c) Incident angle
d) All of the mentioned

View Answer

Answer: d [Reason:] The machining rates or yield depends on material to be machined, type of ions and incident angle.

8. What is the value of voltage required for machining in Ion beam machining?
a) 1 kV
b) 2 kV
c) 3 kV
d) 4 kV

View Answer

Answer: a [Reason:] The value of voltage required for machining in Ion beam machining process is about 1 kV.

9. What are the values of current densities required in IBM?
a) 0.25 mA/cm2
b) 0.35 mA/cm2
c) 0.55 mA/cm2
d) 0.85 mA/cm2

View Answer

Answer: d [Reason:] The value of current density of about 0.85 mA/cm2 is required for machining the work piece materials in Ion beam machining.

10. What is the value of beam diameter that is obtained in IBM?
a) 1 cm
b) 3 cm
c) 5 cm
d) 7 cm

View Answer

Answer: c [Reason:] The value of the beam diameter for machining the work piece material in Ion beam machining is about 5 cm.