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Machining Processes MCQ Set 1

1. In this type of machining, machining forces are controlled by which of the following fields?
a) Magnetic field
b) Electric field
c) Radiative field
d) None of the mentioned

View Answer

Answer: a [Reason:] In this machining, magnetic field controls all the major forces of machining.

2. Which of the following type of tools, are required for magnetic field assisted polishing?
a) Rigid tools
b) Expensive tools
c) Magnetic tools
d) Ultra precession tools

View Answer

Answer: c [Reason:] Magnetic field assisted polishing requires only magnetic machining elements, for the purpose of machining.

3. Which of the following is not a magnetic field assisted machining process?
a) Electro-plating process
b) Magnetic abrasive finishing
c) Magnetic float polishing
d) All of the mentioned

View Answer

Answer: a [Reason:] There are only two types of magnetic field assisted polishing: Magnetic abrasive machining and Magnetic float polishing.

4. In the advanced machining processes, what is the full form of MAF?
a) Magnet Automated Finishing
b) Magnetic Abrasive Finishing
c) Magnet Assisted Floating
d) Magnetic Association for Floating

View Answer

Answer: b [Reason:] In advanced machining processes, full form of MAF is Magnetic Abrasive Finishing.

5. In Magnetic abrasive finishing, which of the following particles do not contribute to the material removal?
a) Abrasive particles
b) Magnetic particles
c) Non-magnetic particles
d) All of the mentioned

View Answer

Answer: c [Reason:] Material is removed by colloidal dispersion of the magnetic particles in abrasive particles.

6. Which of the following motions are opted, in order to carry on with the Magnetic abrasive finishing?
a) Rotary motion
b) Oscillatory motion
c) Vibratory motion
d) All of the mentioned

View Answer

Answer: d [Reason:] All the motions mentioned above, are needed for machining parts in MAF.

7. Magnetic Abrasive finishing is used for which of the following application/s?
a) Surface finishing
b) Cutting
c) Drilling
d) Boring

View Answer

Answer: a [Reason:] Magnetic abrasive finishing is a process, which is opted for finishing of parts that are already machined on the other machines.

8. Which is the place, where Magnetic field assisted polishing was invented?
a) The United States of America
b) The United Arab Emirates
c) Union of Soviet Socialist Republics
d) Japan

View Answer

Answer: a [Reason:] Magnetic field assisted polishing was invented in the United States of America.

9. Which of the following processes cannot be machined using Magnetic abrasive finishing?
a) Surface finishing
b) Surface polishing
c) Hole Drilling
d) None of the mentioned

View Answer

Answer: c [Reason:] Holes drilling is one of the processes that cannot be done using Magnetic Abrasive Finishing.

Machining Processes MCQ Set 2

1. Which type of gap width is necessary for higher degree of accuracy?
a) Very small
b) Small
c) Medium
d) High

View Answer

Answer: b [Reason:] A small gap width represents a high level of accuracy. Very small gap width results in sparks and short circuits.

2. Accuracy of machining is affected by, which of the following factors?
a) Material
b) Gap voltage
c) Feed rate
d) All of the mentioned

View Answer

Answer: d [Reason:] Accuracy of the process is affected by material equivalent, gap voltage, feed rate etc.

3. Which properties of electrolyte does not affect the accuracy of the process?
a) Temperature
b) Concentration
c) Non-reactive
d) Pressure

View Answer

Answer: c [Reason:] Electrolyte must be reactive in order to carry on the reactions that occur at the electrodes.

4. For high process accuracy, which of the following factors are needed?
a) High feed rate
b) High conductivity
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] For higher degree of accuracy, there must be high feed rates and highly conductive electrolytes.

5. Tool insulation that _____ the side machining action is needed in the process of ECM.
a) Limits
b) Enhances
c) Maintains
d) None of the mentioned

View Answer

Answer: a [Reason:] Tool insulation is needed, which limits the machining of other sides of work piece.

6. If the current density is high as required, what type of machining occurs?
a) Pitting
b) Polishing
c) Etching
d) All of the mentioned

View Answer

Answer: b [Reason:] When current density is relatively high as required, then polishing occurs.

7. What happens when current density is low in ECM?
a) Pitting occurs
b) Etching occurs
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] When current density is lower than optimum, then etching and pitting occurs which are undesired.

8. Fine dimensional control can be obtained if throwing power of electrolyte is ____.
a) Low
b) Medium
c) High
d) Very high

View Answer

Answer: a [Reason:] Throwing power of electrolyte must be less in order to obtain a fine dimensional control.

9. Passivation is done on electrolytes in order to form which of the following?
a) Passive layer on machined parts
b) Passive layer on cathode
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: a [Reason:] Passivation is done on the electrolytes in order to form a passive film on machined parts.

10. If there is an increase in the electrolyte flow, what happens to the rate of film formation?
a) Increases
b) Decreases
c) Remains same
d) All of the mentioned

View Answer

Answer: b [Reason:] An increase in electrolytic solution flow decreases the anodic product formation, which reduces the rate of film formation.

11. What are the typical dimensional tolerances for frontal gaps in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm

View Answer

Answer: c [Reason:] The dimensional tolerances obtained for frontal gaps are ± 0.130 mm.

12. What are the tolerance values for the side gap in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm

View Answer

Answer: d [Reason:] The dimensional tolerances obtained for side gaps are ± 0.25 mm.

13. What are the typical dimensional tolerances obtained in ECM when there is proper control of machining?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm

View Answer

Answer: b [Reason:] The dimensional tolerances obtained by proper machining are ± 0.025 mm.

14. It is difficult to machine inner radii smaller than ______ and outer radii less than ____ in ECM.
a) 0.1 mm, 0.2 mm
b) 0.5 mm, 0.8 mm
c) 0.8 mm, 0.5 mm
d) 0.2 mm, 0.1 mm

View Answer

Answer: c [Reason:] It is difficult to machine inner radii < 0.8mm and outer radii < 0.5mm.

15. What is the value of overcut that is obtained using ECM?
a) 0.3 mm
b) 0.5 mm
c) 0.7 mm
d) 0.9 mm

View Answer

Answer: b [Reason:] An overcut of 0.5 mm is obtained when machined using ECM.

Machining Processes MCQ Set 3

1. Non-Traditional machining is recommended when we need which of the following features?
a) Complex shapes
b) High surface quality
c) Low-rigidity structures
d) All of the mentioned

View Answer

Answer: d [Reason:] For above requirements this machining is used.

2. Non-Traditional machining can also be called as?
a) Contact Machining
b) Non-contact machining
c) Partial contact machining
d) Half contact machining

View Answer

Answer: b [Reason:] Tool and work piece are at a distance apart in this type of machining.

3. In which of the following industries, Non-traditional machining methods play an important role?
a) Automobile
b) Aerospace
c) Medical
d) All of the mentioned

View Answer

Answer: d [Reason:] Non-traditional methods are used widely in many industries.

4. Different classifications of Non-traditional machining based on source of energy are?
a) Mechanical
b) Thermal
c) Chemical and electro-chemical.
d) All of the mentioned

View Answer

Answer: d [Reason:] It can be classified into the above mentioned categories.

5. In mechanical machining, material is removed by _____
a) Erosion
b) Corrosion
c) Abrasion
d) Vaporization

View Answer

Answer: a [Reason:] Abrasive grains remove material by mechanical erosion in USM.

6. Material in thermal machining is removed by which of the following means?
a) Vaporization
b) Melting
c) Electro-plating
d) All of the mentioned

View Answer

Answer: d [Reason:] In this machining, heat is the source of energy.

7. Which of the following process comes under mechanical machining?
a) USM
b) EDM
c) LBM
d) PAM

View Answer

Answer: a [Reason:] USM removes material by mechanical erosion.

8. Surface defects that may be occurred during thermal machining are?
a) Micro cracking
b) Heat affected zones
c) Striations
d) All of the mentioned

View Answer

Answer: d [Reason:] During thermal machining surfaces defects occur.

9. Sources used in thermal machining are?
a) Ions
b) Plasma
c) Electrons
d) All of the mentioned

View Answer

Answer: d [Reason:] Different sources are used to remove the materials accordingly.

10. Vacuum is the machining medium for?
a) LBM
b) WJM
c) EBM
d) None of the mentioned

View Answer

Answer: a [Reason:] Vacuum is the medium for Laser Beam Machining and Ion Beam machining.

11. In chemical machining is material removal takes by?
a) Chemical reaction
b) Erosion
c) Electron removal
d) None of the mentioned

View Answer

Answer: a [Reason:] Chemical machining removes material by chemical reactions.

12. An example of hybrid machining?
a) Ultrasonic Machining
b) Electron Beam Machining
c) Ultrasonic assisted electrochemical machining
d) Laser Beam Machining

View Answer

Answer: c [Reason:] More than one phase is used to combine to form hybrid machining.

Machining Processes MCQ Set 4

1. Which of the following are the metals that can be machined using Photo chemical milling?
a) Aluminium
b) Copper
c) Nickel
d) All of the mentioned

View Answer

Answer: d [Reason:] Copper, aluminium, zinc, steel, molybdenum, zirconium, titanium are some of the metals that can be machined using PCM.

2. Which of the following non-metallic materials that can be machined using PCM?
a) Glass
b) Ceramics
c) Some plastics
d) All of the mentioned

View Answer

Answer: d [Reason:] The non-metallic materials mentioned above, can be machined using PCM.

3. Which of the following materials are excellent for Photochemical milling?
a) Brittle materials
b) Ductile materials
c) Elastic materials
d) None of the mentioned

View Answer

Answer: a [Reason:] Brittle materials are excellent candidates for PCM, since they tend to break easily using traditional machining processes.

4. State whether following statement is true or false about applications of PCM.
“Using PCM, very high tempered materials are machined easily.”
a) True
b) False

View Answer

Answer: a [Reason:] PCM can be favourable for very high tempered and brittle materials unlike that of traditional machining, where they tend to break easily.

5. Which of the following are the typical applications of Photo chemical milling?
a) Production of signs
b) Production of labels
c) Fabrication of boxes and enclosures
d) All of the mentioned

View Answer

Answer: d [Reason:] Using PCM, the above mentioned applications can be fulfilled.

6. What is the value of thickness of work pieces to be used in PCM?
a) 0.001 – 0.003 mm
b) 0.013 – 1.50 mm
c) 1.50 – 2.35 mm
d) 2.50 – 3.33 mm

View Answer

Answer: b [Reason:] The thickness value of work pieces in PCM range between 0.013 – 1.50 mm.

7. What type of work pieces must be used in Photochemical milling process?
a) Bent surfaces
b) Rolled surfaces
c) Flat surfaces
d) None of the mentioned

View Answer

Answer: c [Reason:] The work pieces must be flat in order to carry on the PCM process.

8. Which of the following industries use PCM for different applications?
a) Electronic
b) Automotive
c) Telecommunication
d) All of the mentioned

View Answer

Answer: d [Reason:] PCM has its applications in the industries such as electronics, automotive, telecommunication, computer, medical, aerospace and other industries.

9. Which of the following are the components that can be machined using PCM?
a) Filters and screens
b) Lead frames
c) Connectors and probes
d) All of the mentioned

View Answer

Answer: d [Reason:] Typical components such as gaskets, lead frames, contacts, connectors, probes, filters and screens can be machined using PCM.

10. What is the cost per unit for low production volumes of complex designs using PCM?
a) Low
b) Medium
c) High
d) None of the mentioned

View Answer

Answer: a [Reason:] Relatively low cost per unit is required in PCM, since tooling is inexpensive compared to that of traditional practices.

11. State whether following statement is true or false regarding advantages of PCM.
“In PCM, lead times are large, when compared to that required for hard tooling using traditional means.”
a) True
b) False

View Answer

Answer: b [Reason:] Lead times are small when compared to that required by processes that require hard tooling.

12. Which of the following factors can change the parameters of etch such as depth, size of hole etc.?
a) Time of etch
b) Type of etchant
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Type of etchant used and time for etching can change the features such as hole size and depth of etch.

13. How much amount of burr is produced, when components are machined using PCM?
a) Small
b) Medium
c) Large
d) No burr

View Answer

Answer: d [Reason:] Photochemical milling is a burr-free process i.e.., burr is not produced in this process.

14. Which of the following properties of materials are changed by using Photochemical milling?
a) Hardness of material
b) Ductility of material
c) Grain structure
d) None of the mentioned

View Answer

Answer: d [Reason:] In PCM, material properties such as hardness, ductility and grain structure are not changed.

15. State whether following statement is true or false regarding advantages of PCM.
“Patterns can be reproduced easily.”
a) True
b) False

View Answer

Answer: a [Reason:] Patterns can be reproduced easily because, tooling is made by photographic techniques.

Machining Processes MCQ Set 5

1. Which of the following is the first step in Photo chemical milling process?
a) Generation of photographic film
b) Etching the part
c) Removal of etchant
d) Photo resist stripping

View Answer

Answer: a [Reason:] Generation of photographic film using CAD drawings is the first step in PCM.

2. What is the other name for photographic film generated in Photochemical milling?
a) Photo mask
b) Photo tool
c) Photo cover
d) Photo plate

View Answer

Answer: b [Reason:] The photographic film generated using CAD drawings, which is also called as Photo tool.

3. What is the next step after generation of Photo-tool?
a) Chemical cleaning
b) Coating of photo tool
c) None of the mentioned
d) All of the mentioned

View Answer

Answer: d [Reason:] After generation of photo-tool, it is applied to the chemically cleaned work surface.

4. What is the use of photo tool in Photochemical milling process?
a) Cleaning of work piece
b) Protection of surface against etching
c) Etching of part surface
d) None of the mentioned

View Answer

Answer: b [Reason:] In PCM, photo tool is applied as coating which act as stencil resist that protect the surface from etching.

5. Where are the photo tools applied on the surface of the work piece material?
a) On the top
b) On the bottom
c) All of the mentioned
d) None of the mentioned

View Answer

Answer: c [Reason:] Photo tools are applied in pairs- one on the top and one on the bottom like sandwiching work piece between photo layers.

6. The photo tool is exposed to which light source, in order to form a replica of image of the required geometry?
a) Infrared sources
b) Ultraviolet source
c) Normal light source
d) None of the mentioned

View Answer

Answer: b [Reason:] Ultraviolet light sources are used to transfer the image of the required geometry on to the resist, precisely.

7. Which can be used as solutions which develop the photo resists in PCM?
a) Water
b) Alkaline solution
c) Hydrocarbons
d) All of the mentioned

View Answer

Answer: d [Reason:] In PCM, the solutions mentioned above can be used to develop the photoresist films on the surfaces.

8. What is the next step after creating the photo tool and adhering it to work piece using UV light source?
a) Finishing
b) Etching
c) Rinsing and drying
d) None of the mentioned

View Answer

Answer: b [Reason:] After the image is adhered to work piece, etching is done.

9. The right choice of etchant depend on, which of the following factors?
a) Rate of material removal
b) Etching depth
c) Cost and quality
d) All of the mentioned

View Answer

Answer: d [Reason:] Etchant selection depends on cost, quality, etch depth and MRR rate.

10. After etching is done, what is the next step in Photochemical milling process?
a) Finishing
b) Rinsing and drying
c) Removal of protective layer
d) None of the mentioned

View Answer

Answer: b [Reason:] After etching is done in PCM, the parts are rinsed and dried.

11. How are the protective layer coatings on the parts are removed?
a) Use of chemicals
b) Mechanical techniques with chemicals
c) None of the mentioned
d) All of the mentioned

View Answer

Answer: d [Reason:] The protective layers are removed by the use of chemical and by using mechanical techniques with chemicals.