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## Machining Processes MCQ Set 1

1. Which of the following distribution factors, does not affect the machining parts?
a) Side wear of tool
b) Abrasive wear
c) Accurate feed
d) Form error of tool

### View Answer

Answer: c [Reason:] Inaccurate feed is the factor that affects the accuracy of machining parts.

2. Of the following factors, which one affects the accuracy of parts?
a) Steady abrasive flow
b) Accurate feed
c) Unsteady abrasive flow
d) Ultrasonic frequency

### View Answer

Answer: c [Reason:] Unsteady and uneven abrasive flow affects the dimensional accuracy.

3. State whether the statement is true or false.
“Hole oversize measures the difference between hole diameter measured at the bottom surface, and the tool diameter.”
a) True
b) False

### View Answer

Answer: b [Reason:] Oversize measures the difference of the hole diameter measured at top surface.

4. While machining W4C and glass, tool over cut size when compared to mean grain size is?
a) Two times greater
b) Two times smaller
c) Three times greater
d) Three times smaller

### View Answer

Answer: a [Reason:] Tool over cut size is 2 or 4 times greater than mean grain size.

5. While machining B4C, tool over cut size when compared to mean grain size is?
a) Two times greater
b) Two times smaller
c) Three times greater
d) Three times smaller

### View Answer

Answer: c [Reason:] Tool over cut is 3 times greater than mean grain size while machining B4C.

6. Of the following, USM accuracy levels are limited to which value?
a) ± 0.01 mm
b) ± 0.05 mm
c) ± 0.10 mm
d) ± 0.50 mm

### View Answer

Answer: b [Reason:] In Ultrasonic Machining the dimensional accuracy levels are limited to ± 0.05mm.

7. Conicity resulting after machining by Ultrasonic Machining can be reduced by?
a) Direct injection of slurry
b) Tools having negative taper
c) High static pressure
d) All of the mentioned

### View Answer

Answer: d [Reason:] Conicity can be reduced by above means and also by using wear resistant tools, finer abrasive particles etc.

8. Typical roundness error in graphite, resulted due to lateral vibrations is between?
a) 01 – 20 μm
b) 20 – 60 μm
c) 60 – 100 μm
d) 100 – 150 μm

### View Answer

Answer: b [Reason:] The roundness is between 20 – 60 μm while machining graphite by Ultrasonic Machining.

9. Typical roundness error in glass, resulted due to lateral vibrations is between?
a) 01 –20 μm
b) 20 – 40 μm
c) 40 – 140 μm
d) 150 – 250 μm

### View Answer

Answer: c [Reason:] The roundness is between 40 – 140 μm while machining graphite by Ultrasonic Machining.

10. Which of the following factors affect the surface finish of machined parts in Ultrasonic Machining?
a) Amplitude
b) Material
c) Tool surface
d) All of the mentioned

### View Answer

Answer: d [Reason:] The above factors influence the surface quality of the machined parts in Ultrasonic Machining very significantly.

11. What is value of surface finish achieved, when we use the abrasive of grit number 240?
a) 0.01 – 0.08 μm
b) 0.08 – 0.13 μm
c) 0.13 – 0.25 μm
d) 0.25 – 0.38 μm

### View Answer

Answer: d [Reason:] The surface roughness obtained, when machined using abrasive of grit number 240, is between 0.25 – 0.38 μm.

12. When the viscosity of liquid carrier is increased, the surface quality of the parts?
a) Increased
b) Decreased
c) Remained same
d) None of the mentioned

### View Answer

Answer: c [Reason:] As the viscosity of the liquid carriers reduces we can obtain smoother surfaces.

## Machining Processes MCQ Set 2

1. What happens to MRR with increase in tool amplitude?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned

### View Answer

Answer: a [Reason:] As amplitude of the tool increases, rate of material removal increases.

2. The vibration amplitude determines, which parameter of the abrasive particles?
a) Force
b) Torque
c) Velocity
d) Pressure

### View Answer

Answer: c [Reason:] Amplitude determines the velocity of abrasive particles between tool and work piece.

3. State whether the statement is true or false.
“If splashing occurs, it will result in the increase of material removal rate in USM.”
a) True
b) False

### View Answer

Answer: b [Reason:] Splashing occurs if amplitude is very high which in turn decreases the material removal rate.

4. Amplitude of the oscillation ranges between which of the following values?
a) 0.01 – 0.04 mm
b) 0.04 – 0.08 mm
c) 0.08 – 0.10 mm
d) 0.10 – 0.20 mm

### View Answer

Answer: b [Reason:] Optimum value of the amplitude of the tool will vary between 0.04-0.08 mm.

5. As the vibration frequency increases, what happens to material removal rate?
a) Decreases
b) Increases
c) Increase and then decrease
d) Decrease and then increase

### View Answer

Answer: c [Reason:] Up to a certain limit of vibration frequency, MRR increases and after that it decreases.

6. Of the following, which one can be used as abrasive carrying medium?
a) Water
b) Benzene
c) Glycerol
d) All of the mentioned

### View Answer

Answer: d [Reason:] Any of the above liquids can be used as abrasive carrying medium.

7. If there is an increase in viscosity of slurry, what happens to MRR?
a) Increases
b) Decreases
c) Remains same
d) None of the mentioned

### View Answer

Answer: b [Reason:] As viscosity is increased, material removal rate is decreased.

8. How much percent of the abrasives are recommended in general for abrasive medium?
a) 10 – 15 %
b) 15 – 20 %
c) 25 – 30 %
d) 30 – 35 %

### View Answer

Answer: d [Reason:] In practice, volumetric concentration of abrasives used range between 30 – 35 %.

9. State whether the following statement is true or false.
“Machining rate can be affected by the ratio of hardness of tool to that of hardness of work piece.”
a) True
b) False

### View Answer

Answer: a [Reason:] In USM, Machining rate increases as the mentioned ratio decreases and vice-versa.

10. As the tool area increases, what happens to MRR?
a) Decreases
b) Increases
c) Remains same
d) None of the mentioned

### View Answer

Answer: a [Reason:] An increase in tool area distributes grains over the work piece, which reduces the machining rate.

11. When the static pressure of the feed is increases, what happens to MRR?
a) Increases
b) Decreases
c) Increase up to a limiting condition
d) Decrease up to a limiting condition

### View Answer

Answer: c [Reason:] As static feed pressure increases, MRR increase up to a limiting condition and then no further increase takes place.

## Machining Processes MCQ Set 3

1. The machining system of USM contains which of the following components?
a) Magnetostrictor
b) Concentrator
c) Tools and slurry
d) All of the mentioned

### View Answer

Answer: d [Reason:] In machining system of USM, the above mentioned components have to be present.

2. State whether following statement is true or false.
“In Ultrasonic Machining, Magnetostrictor is energized at ultrasonic frequency.”
a) True
b) False

### View Answer

Answer: a [Reason:] To oscillate, magnetostrictor must be energized to ultrasonic frequency in USM.

3. Of the following scientists, who discovered magnetostrictor effect?
a) Balamuth
b) Steve O Flawer
c) Joule
d) Turing

### View Answer

Answer: c [Reason:] This effect was discovered by Joule in 1874 at Manchester.

4. In Ultrasonic Machining, magnetostrictor converts magnetic energy into which type of energy?
a) Mechanical energy
b) Electrical energy
c) Thermal energy
d) None of the mentioned

### View Answer

Answer: a [Reason:] Oscillation of magnetostrictor takes place by converting magnetic energy to mechanical energy.

5. What is the value of the amplitude obtained without mechanical amplifier?
a) 0.0001 – 0.001 µm
b) 0.001 – 0.1 µm
c) 1 – 10 µm
d) 10 – 100 µm

### View Answer

Answer: b [Reason:] Relatively very small amplitudes are obtained without amplifier.

6. What is the value of the amplitude obtained when we use mechanical amplifier?
a) 1 – 10 µm
b) 10 – 40 µm
c) 40 – 50 µm
d) 50 – 100 µm

### View Answer

Answer: c [Reason:] Relatively larger amplitudes are obtained when amplifier is used.

7. State whether the following statement is true or false.
“In USM, tool tips must have low resistance and fatigue strength.”
a) True
b) False

### View Answer

Answer: b [Reason:] In USM, tool tips should must have high wear resistance and fatigue strength.

8. At what rate slurry is pumped through nozzle in USM?
a) 10 L/min
b) 25 L/min
c) 50 L/min
d) 75 L/min

### View Answer

Answer: b [Reason:] Slurry is pumped through nozzle at the rate of 25 L/min, L- litres.

## Machining Processes MCQ Set 4

1. By which of the following means, material is removed in USM?
a) Mechanical abrasion
b) Microchipping
c) Cavitation
d) All of the mentioned

### View Answer

Answer: d [Reason:] In Ultrasonic Machining, material is removed by any of the above means.

2. What is the percentage of contribution of cavitation to the total material removed?
a) <5%
b) 5 – 10 %
c) 10 – 20 %
d) 20 – 50 %

### View Answer

Answer: a [Reason:] Cavitation contributes to only less than 5 % of total material removed.

3. The following mechanisms, which one is dominant in material removal?
a) Hammering
b) Cavitation
c) Microchipping
d) None of the mentioned

### View Answer

Answer: a [Reason:] Hammering is dominant mechanism in material removal of USM.

4. When machining porous material, which type of mechanism is introduces?
a) Abrasion
b) Erosion
c) Corrosion
d) Vaporization

### View Answer

Answer: b [Reason:] Material removal of porous material takes place by erosion.

5. The rate of material removal depends on which of the following features?
a) Frequency
b) Static Pressure
c) Machining area
d) All of the mentioned

### View Answer

Answer: d [Reason:] Material removal rate depends on all the above mentioned factors.

6. State whether following statement is true or false.
“The machinability of USM depends on brittleness criterion.”
a) True
b) False

### View Answer

Answer: a [Reason:] Both machinability and MRR depends on brittleness of material.

7. Which of the following are the features of tool affecting MRR in USM?
a) Hardness
b) Wearability
c) Accuracy
d) Mounting

### View Answer

Answer: d [Reason:] Different features of tool also affect the material removal in USM.

8. What is the machinability rate of glass by USM?
a) 25%
b) 50%
c) 75%
d) 100%

### View Answer

Answer: d [Reason:] In case of brittle materials, Ultrasonic Machining’s MRR is very high.

## Machining Processes MCQ Set 5

1. What is the full form of WJM in advanced machining processes?
a) Water Jack Manufacturing
b) Water Jet Machining
c) Water Jet Manufacturing
d) Water Jack Manufacturing

### View Answer

Answer: b [Reason:] The full form of WJM is water jet machining in advanced machining processes.

2. What is the key element of water jet machining for material removal?
a) Tool Holder
b) Work piece
c) Water jet
d) Power source

### View Answer

Answer: c [Reason:] Water jet is the one, which is used to cut the work piece and to remove material.

3. What is the velocity of water jet stream in water jet machining?
a) 100 m/sec
b) 300 m/sec
c) 700 m/sec
d) 900 m/sec

### View Answer

Answer: d [Reason:] Velocity of water jet stream that is used in Water jet machining is about 900 m/sec.

4. Which of the following is not a part of machining system of Water jet machining?
a) Transducer
b) Accumulator
c) Jet cutting nozzle
d) Hydraulic pump

### View Answer

Answer: a [Reason:] Transducer is not a part of Water jet machining and other components come under WJM.

5. What is the general power rating of the hydraulic pump, used in WJM?
a) 10 kW
b) 20 kW
c) 30 kW
d) 40 kW

### View Answer

Answer: c [Reason:] The power rating of the motor of hydraulic pump, which is used in WJM is about 30 kW.

6. Which of the following are the components of intensifier present in water jet machining system?
a) Piston
b) Plunger
c) Limit switch
d) All of the mentioned.

### View Answer

Answer: d [Reason:] The above mentioned components are present in the intensifier of water jet machining.

7. Intensifier increases the pressure water by which of the following values?
a) 10 – 100 MPa
b) 100 – 200 MPa
c) 200 – 400 MPa
d) 400 – 1000 MPa

### View Answer

Answer: c [Reason:] Use of intensifier is to increase the inlet water pressure to 200 – 400 MPa.

8. On which property of water, will the accumulator in Water jet machining rely on?
a) Density
b) Compressibility
c) Viscosity
d) Velocity

### View Answer

Answer: b [Reason:] Accumulator relies on compressibility of water (12% at 3800bar), in order to maintain a uniform discharge pressure in WJM.

9. What are the values of typical tube diameters in the machining system in WJM?
a) 0.1 to 1 mm
b) 1 to 6 mm
c) 6 to 14 mm
d) 14 to 25 mm

### View Answer

Answer: c [Reason:] Typical tube diameter values range between 6 to 14 mm.

10. What is the expected life of the nozzles used in WJM?
a) 10 hrs
b) 20 hrs
c) 100 hrs
d) 200 hrs

### View Answer

Answer: d [Reason:] The life that is expected from the nozzle, which is a part of machining system, is 200 hrs.

11. Which of the following does not damage the nozzle used in Water jet machining?
a) Particles of dirt
b) Mineral deposits
c) Water
d) All of the mentioned

### View Answer

Answer: c [Reason:] Only dirt particles and mineral deposits are responsible for damage of nozzle.

12. What are the uses of catcher in machining system of Water jet machining?
a) Collecting dirt
b) Collection of debris
c) Reduce noise levels
d) All of the mentioned

### View Answer

Answer: d [Reason:] Catcher in WJM is used to collect the dirt, machined debris and reduce the noise levels.

## Machining Processes MCQ Set 6

1. In how many directions, can the cutting takes place in Water jet machining?
a) Uni-directional
b) Bi-directional
c) Multi-directional
d) None of the mentioned

### View Answer

Answer: c [Reason:] Water jet machining has multi directional cutting capacity i.e.., in any direction in three dimensional space.

2. In Water jet machining, cuts can be started at which place of work piece?
a) From left
b) From right
c) From middle
d) From any point

### View Answer

Answer: d [Reason:] In WJM, cuts can be started from any point on the work piece.

3. State whether following statement is true or false.
“To start the cuts in Water jet machining, pre-drilled holes are not necessary.”
a) True
b) False

### View Answer

Answer: b [Reason:] In Water jet machining, we need not require any pre-drilled holes to start the cuts.

4. Which of the following is not an advantage of Water jet machining?
a) Burr produced is minimal
b) No Heat is produced
c) Relatively low hourly rates
d) Environmentally safe

### View Answer

Answer: c [Reason:] Costs per hour are relatively high in Water jet machining.

5. State whether following statement is true or false.
“In Water jet machining, tool need not require sharpening once the machining is done.”
a) True
b) False

### View Answer

Answer: a [Reason:] Tool does not wear in water jet machining, so it need not be sharpened.

6. Which of the following secondary processes are eliminated in Water jet machining?
a) Grinding of surface
b) Surface treatment
c) Polishing of surface
d) All of the mentioned

### View Answer

Answer: d [Reason:] All the mentioned secondary processes above, are eliminated in Water jet machining.

7. How many parts are cut using Water jet machining, on a single blank?
a) One part
b) Two parts
c) Three parts
d) Multiple parts

### View Answer

Answer: d [Reason:] Depending up on the kerf width, multiple parts can be machined using single blank.

8. Which of the following is the disadvantage of water jet machining?
a) Narrow kerf width
b) Small diameter of nozzle
c) Not suitable for mass production
d) Burr is minimal

### View Answer

Answer: c [Reason:] Due to high maintenance, WJM cannot be used for mass production.

## Machining Processes MCQ Set 7

1. In the following materials, Water jet machining can be used on which type of material?
a) Metals
b) Plastics
c) Ceramics
d) All of the mentioned

### View Answer

Answer: d [Reason:] WJM can be used on metals, cloth, paper, plastics, food, leather and ceramics.

2. What are the processes and applications, where Water jet machining can be used?
a) Cutting
b) Drilling
c) Deburring
d) All of the mentioned

### View Answer

Answer: d [Reason:] Water jet machining can be used for drilling, cutting, deburring, surface treatment and many more applications.

3. What are the tolerance limits range of thin materials in WJM?
a) ± 0.1 mm
b) ± 10 mm
c) ± 25 mm
d) ± 50 mm

### View Answer

Answer: c [Reason:] In Water jet machining, the range of tolerance is ± 25 mm.

4. In cutting of rocks using water jet machining, which type of pressure is needed?
a) Low pressure
b) Medium pressure
c) High pressure
d) None of the mentioned

### View Answer

Answer: c [Reason:] In WJM, very high pressures and velocities are needed while cutting rocks.

5. In deburring, which combination removes the material from non-metallic materials?
a) High pressure and low flow rate
b) High pressure and high flow rate
c) Low pressure and low flow rate
d) Low pressure and high flow rate

### View Answer

Answer: a [Reason:] For non-metallic materials high pressure and lower flow rates are used in deburring.

6. Which of the following materials has some drawbacks of cutting WJM?
a) Food
b) Rocks
c) Fibre-reinforced plastics
d) None of the mentioned

### View Answer

Answer: c [Reason:] Water gets deflected due to the fibre embedded in the matrix of fibre-reinforced plastics, when we use WJM.

7. What is the accuracy level obtained when PCB’s are cut by WJM?
a) ± 0.05 mm
b) ± 0.13 mm
c) ± 0.26 mm
d) ± 0.33 mm

### View Answer

Answer: b [Reason:] In WJM, accuracy obtained in cutting of PCB’s is ± 0.13 mm.

8. In WJM, surface treatment includes which type of processes?
a) Removing deposits
b) Removing chemicals
c) Degreasing
d) All of the mentioned

### View Answer

Answer: d [Reason:] Surface treatment is done using WJM to clean the surface from many toxic chemical, deposits, residues etc.

## Machining Processes MCQ Set 8

1. Distance between which components, is the stand-off distance?
a) Nozzle-inlet and work piece top
b) Nozzle-outlet and work piece-top
c) Nozzle-inlet and work piece-bottom
d) Nozzle-outlet and work piece-bottom

### View Answer

Answer: b [Reason:] Stand-off distance is the distance between top of work piece and nozzle outlet.

2. What is the value of diameter of the jet cutting nozzle in WJM?
a) 0.01 – 0.1 mm
b) 0.1 – 0.3 mm
c) 0.3 – 0.7 mm
d) 0.7 – 1.5 mm

### View Answer

Answer: b [Reason:] In WJM, diameter of the nozzles range between 0.10 – 0.30 mm.

3. What is the value of stand-off distance in Water jet machining?
a) 0.1 – 1 mm
b) 1 – 2 mm
c) 2 – 6 mm
d) 6 – 14 mm

### View Answer

Answer: c [Reason:] Stand-off distance value ranges between 2.5 – 6 mm in Water jet machining.

4. What are the values of jet velocities in Water jet machining?
a) 100 – 200 m/s
b) 200 – 500 m/s
c) 500 – 1500 m/s
d) 1500 – 3000 m/s

### View Answer

Answer: c [Reason:] Velocity of the water jet stream ranges between 540 – 1480 m/s in WJM.

5. State whether the following statement is true or false.
“As the pump pressure increases, depth of cut decreases in Water jet machining.”
a) True
b) False

### View Answer

Answer: b [Reason:] As the pump pressure is increases, the depth of cut also increases in WJM.

6. What is the value of material thickness of work piece in WJM?
a) 0.001 – 0.25 mm
b) 0.8 – 25 mm
c) 50 – 100 mm
d) 100 – 500 mm

### View Answer

Answer: b [Reason:] The material thickness value of work piece range between 0.8 – 25 mm.

7. What is the value of feed rate in Water Jet Machining?
a) 0.0001 – 0.025 m/min
b) 0.05 – 0.25 m/min
c) 0.5 – 200 m/min
d) 200 – 500 m/min

### View Answer

Answer: c [Reason:] In Water jet machining, value of the feed rate ranges between 0.5 – 200 m/min.

8. In WJM, what are the properties of jet fluid that affect the MRR?
a) Velocity
b) Flow rate
c) Viscosity
d) All of the mentioned

### View Answer

Answer: d [Reason:] All the mentioned properties above, of jet fluid affect the MRR in Water jet machining.

9. Which of the following property/ies of nozzle does not affect the material removal rate in Water jet machining?
a) Material
b) Diameter
c) Outside temperature
d) Stand-off distance

### View Answer

Answer: c [Reason:] In nozzle, outside temperature has no effect on the rate of material removal.

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