Unconventional Machining Processes MCQ Quiz in मल्याळम - Objective Question with Answer for Unconventional Machining Processes - സൗജന്യ PDF ഡൗൺലോഡ് ചെയ്യുക

Last updated on Apr 14, 2025

നേടുക Unconventional Machining Processes ഉത്തരങ്ങളും വിശദമായ പരിഹാരങ്ങളുമുള്ള മൾട്ടിപ്പിൾ ചോയ്സ് ചോദ്യങ്ങൾ (MCQ ക്വിസ്). ഇവ സൗജന്യമായി ഡൗൺലോഡ് ചെയ്യുക Unconventional Machining Processes MCQ ക്വിസ് പിഡിഎഫ്, ബാങ്കിംഗ്, എസ്എസ്‌സി, റെയിൽവേ, യുപിഎസ്‌സി, സ്റ്റേറ്റ് പിഎസ്‌സി തുടങ്ങിയ നിങ്ങളുടെ വരാനിരിക്കുന്ന പരീക്ഷകൾക്കായി തയ്യാറെടുക്കുക

Latest Unconventional Machining Processes MCQ Objective Questions

Top Unconventional Machining Processes MCQ Objective Questions

Unconventional Machining Processes Question 1:

Which of the following is not generally machined by Ultra Sonic Machining (USM)?

  1. Copper
  2. Glass
  3. Silicon
  4. Germanium

Answer (Detailed Solution Below)

Option 1 : Copper

Unconventional Machining Processes Question 1 Detailed Solution

Explanation:

Ultra Sonic Machining (USM):

  • Ultrasonic machining is a non-conventional machining process. USM has grouped under the mechanical group non-conventional machining processes.
  • In ultrasonic machining, a tool of the desired shape vibrates at an ultrasonic frequency (19 ~ 25 kHz) with an amplitude of around 15 – 50 μm over the workpiece.
  • Generally, the tool is pressed downward with a feed force, F between the tool and workpiece.
  • The machining zone is flooded with hard abrasive particles generally in the form of a water-based slurry.
  • As the tool vibrates over the workpiece, the abrasive particles act as the indenters and indent both the work material and the tool.
  • The abrasive particles, as they indent, the work material, would remove the same, particularly if the work material is brittle, due to crack initiation, propagation, and brittle fracture of the material.
  • Hence, USM is mainly used for machining brittle materials which are poor conductors of electricity and thus cannot be processed by Electrochemical and Electro-discharge machining. 

F1 S.S D.K 20.07.2019 D 5

Unconventional Machining Processes Question 2:

The source of energy in ultrasonic machining process is

  1. Mechanical
  2. Electrical
  3. Electric spark
  4. None of these

Answer (Detailed Solution Below)

Option 1 : Mechanical

Unconventional Machining Processes Question 2 Detailed Solution

Concept:

Ultrasonic machining is an operation that involves a vibrating tool fluctuating at the ultrasonic frequencies to remove the material from the workpiece.

The process involves an abrasive slurry that runs between the tool and the workpiece.

It is typically used on brittle materials as well as materials with a high hardness due to the microcracking mechanics.

F1 S.S D.K 20.07.2019 D 5

So, the source of energy used in ultrasonic machining is mechanical.

Unconventional Machining Processes Question 3:

In ultrasonic machining process, the material removal rate would

  1. Increase
  2. Decrease
  3. Increase and then decrease
  4. Decrease and then increase

Answer (Detailed Solution Below)

Option 3 :
Increase and then decrease

Unconventional Machining Processes Question 3 Detailed Solution

Concept:

Ultrasonic machining (USM):

  • Ultrasonic machining is an operation that involves a vibrating tool fluctuating at the ultrasonic frequencies to remove the material from the workpiece.
  • The process involves an abrasive slurry that runs between the tool and the workpiece.
  • It is typically used on brittle materials as well as materials with a high hardness due to microcracking mechanics.

F1 S.S D.K 20.07.2019 D 5

  • In ultrasonic machining, a tool of the desired shape vibrates at an ultrasonic frequency (19 ∼ 25 kHz) with an amplitude of around 15 – 50 μm over the workpiece.
  • Generally, the tool is pressed downward with a feed force, F.
  • Between the tool and workpiece, the machining zone is flooded with hard abrasive particles generally in the form of a water-based slurry.
  • As the tool vibrates over the workpiece, the abrasive particles act as the indenters and indent both the work material and the tool.
  • The abrasive particles, as they indent the work material, would remove the work material, particularly if the work material is brittle (due to crack initiation, propagation and brittle fracture of the material).

USM MRR vs Feed Force

With an increase in the frequency of the tool head, the MRR should increase proportionally. However, there is a slight variation in the MRR with frequency. 

MRR increases with increasing feed force but after a certain critical feed force, it decreases because the abrasive grains get crushed under heavy load.

With increases of feed force, the material removal rate MRR is first increases and then decreases.

F1 S.S Madhu 10.12.19 D 17

Confusion PointsThe relation of MRR with the parameter feed force has not been mentioned in the question and has been asked in the official exam in this manner only.

Unconventional Machining Processes Question 4:

The process, that uses a tapered horn to amplify and focus the mechanical energy for machining of glass, is

  1. electrochemical machining
  2. electrical discharge machining
  3. ultrasonic machining
  4. abrasive jet machining

Answer (Detailed Solution Below)

Option 3 : ultrasonic machining

Unconventional Machining Processes Question 4 Detailed Solution

Explanation:

The unconventional machining process and their characteristics and the application areas are discussed in the table below:

Type Of Machining

Mechanics Of Material Removal

Medium

Tool Material

Material Application

Ultrasonic machining

Brittle fracture caused by the impact of abrasive grain due to tool vibrating at high frequency (Amplified by tapered horn).

Slurry

Tough and ductile (soft steel)

The hard and brittle material, semiconductor, non-metals( eg. Glass and ceramic).

Abrasive Jet Machining

Brittle fracture by impinging abrasive grains at high speed.

Air, CO2

Abrasives (Al2O3, ­­SiC),

Nozzle (WC, sapphire)

Hard and Brittle metal and non-metallic material.

Electric discharge machining

Melting and evaporation, aided by cavitation.

Dielectric fluid

Copper, brass, graphite

All conducting metals and alloys

Electrochemical machining

Electrolysis

Conducting electrolyte

Copper, brass, steel

All conducting metals and alloys

Electron beam machining

Melting and vapourisation

vacuum

A beam of an electron moving at high velocity

All material.

Laser beam machining

Melting and vapourisation

Normal atmosphere

A high power laser beam (Ruby rod)

All material.

Unconventional Machining Processes Question 5:

The non-traditional machining process that essentially requires vacuum is 

  1. electron beam machining
  2. electro chemical machining
  3. electro chemical discharge machining
  4. electro discharge machining

Answer (Detailed Solution Below)

Option 1 : electron beam machining

Unconventional Machining Processes Question 5 Detailed Solution

Explanation:

Electron Beam Machining (EBM): In this machining workpiece placed in the vacuum chamber and High‐voltage electron beam directed toward the workpiece. The energy of electron beam melts/ vaporizes selected region of the workpiece. The electron beam is moved by deflection coils.

The operation is performed in the vacuum to prevent the reduction of electron velocity.

Important Points

Type Of Machining

Mechanics Of Material Removal

Medium

Tool Material

Material Application

Ultrasonic machining

Brittle fracture caused by the impact of abrasive grain due to tool vibrating at high frequency (Amplified by tapered horn).

Slurry

Tough and ductile (soft steel)

The hard and brittle material, semiconductor, non-metals( eg. Glass and ceramic).

Abrasive Jet Machining

Brittle fracture by impinging abrasive grains at high speed.

Air, CO2

Abrasives (Al2O3, ­­SiC),

Nozzle (WC, sapphire)

Hard and Brittle metal and non-metallic material.

Electric discharge machining

Melting and evaporation, aided by cavitation.

Dielectric fluid

Copper, brass, graphite

All conducting metals and alloys

Electrochemical machining

Electrolysis

Conducting electrolyte

Copper, brass, steel

All conducting metals and alloys

Electron beam machining

Melting and vapourisation

vacuum

A beam of an electron moving at high velocity

All material.

Laser beam machining

Melting and vapourisation

Normal atmosphere

A high power laser beam (Ruby rod)

All material.

Unconventional Machining Processes Question 6:

Which of the following figure represents the effect of nozzle tip distance (NTD) on material removal rate (MRR) in abrasive jet machining (AJM)?

  1. F1 V.S. Nita 07.10.2019 D 1
  2. F1 V.S. Nita 07.10.2019 D 2
  3. F1 V.S. Nita 07.10.2019 D 3
  4. F1 V.S. Nita 07.10.2019 D 4

Answer (Detailed Solution Below)

Option 4 : F1 V.S. Nita 07.10.2019 D 4

Unconventional Machining Processes Question 6 Detailed Solution

Explanation:

Abrasive jet machining (AJM)

  • In abrasive jet, machining material removal takes place due to the impingement of the fine abrasive particles. These particles move with a high-speed air (or gas) stream. The abrasive particles are typically are of 0.025 mm diameter.
  • When an abrasive particle impinges on the work surface at a high velocity, the impact causes a tiny brittle fracture and the flowing air carries away the dislodgedged small workpiece particle.
  • This process is more suitable when the work material is brittle and fragile.
  • One of the most important factors in the AJM is the distance between the work surface and the tip of the nozzle normally called The nozzle tip distance (NTD). NTD affects not only the material removal rate (MRR) from the work surface but also the shape and size of the cavity produced. When the NTD increases, the velocity of the abrasive particle impinging on the work surface increases due to their acceleration after they leave the nozzle. This in turn increase MRR. With the further increase in NTD, the velocity reduces due to the drag of the atmosphere which initial checks the increase in MRR and finally decreases it.
  • The variation of MRR with NTD is given below.

F1 V.S. Nita 07.10.2019 D 4

Unconventional Machining Processes Question 7:

The frequency of pulsing in a die-sinking electric discharge machine (EDM) is 10 kHz. The pulse off-time is set at 40 micro-seconds. The duty factor at this setting is

  1. 0.40
  2. 0.60
  3. 0.67
  4. 2.50

Answer (Detailed Solution Below)

Option 2 : 0.60

Unconventional Machining Processes Question 7 Detailed Solution

Concept:

\(Duty\ factor = \frac{Pulse \ on \ time}{Total\ time}\)

Calculation:

Given:

Frequency (f) = 10 kHz, Pulse off-time = 40 μs

\(Total \ time =\frac{1}{10\ \times10^3 }\) s

Total time = 100 μs

Pulse on time = Total Time - Pulse off-time

Pulse on time = 100 - 40 = 60 μs

\(Duty\ factor = \frac{Pulse \ on \ time}{Total\ time}\)

\(Duty\ factor = \frac{60}{100}\)

Duty factor = 0.6

Unconventional Machining Processes Question 8:

Which one of the following statements is true for the Ultrasonic Machining (USM) Process?

  1. In USM, the tool vibrates at subsonic frequency
  2. USM is an excellent process for machining ductile materials
  3. USM often uses a slurry comprising abrasive particles and water
  4. All the above

Answer (Detailed Solution Below)

Option 3 : USM often uses a slurry comprising abrasive particles and water

Unconventional Machining Processes Question 8 Detailed Solution

Explanation:

Ultrasonic machining (USM):

  • Ultrasonic machining is an operation that involves a vibrating tool fluctuating at the ultrasonic frequencies to remove the material from the workpiece.
  • The process involves an abrasive slurry that runs between the tool and the workpiece.
  • It is typically used on brittle materials as well as materials with a high hardness due to microcracking mechanics.

F1 S.S D.K 20.07.2019 D 5

  • In ultrasonic machining, a tool of the desired shape vibrates at an ultrasonic frequency (19 ∼ 25 kHz) with an amplitude of around 15 – 50 μm over the workpiece.
  • Generally, the tool is pressed downward with a feed force, F.
  • Between the tool and workpiece, the machining zone is flooded with hard abrasive particles generally in the form of a water-based slurry.
  • As the tool vibrates over the workpiece, the abrasive particles act as the indenters and indent both the work material and the tool.
  • The abrasive particles, as they indent the work material, would remove the work material, particularly if the work material is brittle (due to crack initiation, propagation and brittle fracture of the material).

Additional Information

USM MRR (Material Removal Rate) vs Feed Force

With an increase in the frequency of the tool head, the MRR should increase proportionally. However, there is a slight variation in the MRR with frequency. 

MRR increases with increasing feed force but after a certain critical feed force, it decreases because the abrasive grains get crushed under heavy load.

With increases in feed force, the material removal rate MRR is first increases and then decreases.

F1 S.S Madhu 10.12.19 D 17

Unconventional Machining Processes Question 9:

Which one of the following processes does not cause tool wear?

  1. Ultrasonic machining
  2. Electric discharge machining
  3. Electrochemical machining
  4. All of them

Answer (Detailed Solution Below)

Option 3 : Electrochemical machining

Unconventional Machining Processes Question 9 Detailed Solution

Explanation:

In ECM, there is no mechanical contact between the workpiece and the cutting tool and hence there is no possibility of tool wear. The material from the workpiece is removed by the chemical action of the electrolyte using Faraday’s law of electrolysis. Workpiece forms electrode (anode) and the cutting tool negative electrode (cathode).

The tool material used in ECM should have following property

  • It should have high electrical conductivity
  • It should be easily machinable and it should have high stiffness
  • Its corrosion resistance should be high.


The advantages of ECM include

  • Complex shapes can be made accurately
  • The surface finish is good due to atomic level dissolution
  • Tool wear practically absent
  • Its material removal rate is highest.

Unconventional Machining Processes Question 10:

________ process is used for making a complicated contour in carbide piece.

  1. Laser machining
  2. Electro-chemical milling
  3. Plasma arc machining
  4. Electro-discharge machining

Answer (Detailed Solution Below)

Option 4 : Electro-discharge machining

Unconventional Machining Processes Question 10 Detailed Solution

Explanation:

Some of the non-conventional machining processes and their shape applications are explained below:

Process

Shape (Job) Application

Ultrasonic Machining

Round and irregular holes, impressions

Abrasive jet Machining

Drilling, cutting, deburring, etching, cleaning

Electric discharge machining

Blind complex cavities, micro holes for nozzles, through cutting of non-circular holes, narrow slots.

Electrochemical machining

Blind complex cavities, curved surfaces, through cutting, large through cutting

Laser beam machining

drilling fine holes.

Electron beam machining

Drilling fine holes, cutting contours in sheets, cutting narrow slots.

Important Points

Type Of Machining

Mechanics Of Material Removal

Medium

Tool Material

Material Application

Ultrasonic machining

Brittle fracture caused by the impact of abrasive grain due to tool vibrating at high frequency (Amplified by tapered horn).

Slurry

Tough and ductile (soft steel)

The hard and brittle material, semiconductor, non-metals( eg. Glass and ceramic).

Abrasive Jet Machining

Brittle fracture by impinging abrasive grains at high speed.

Air, CO2

Abrasives (Al2O3, ­­SiC),

Nozzle (WC, sapphire)

Hard and Brittle metal and non-metallic material.

Electric discharge machining

Melting and evaporation, aided by cavitation.

Dielectric fluid

Copper, brass, graphite

All conducting metals and alloys

Electrochemical machining

Electrolysis

Conducting electrolyte

Copper, brass, steel

All conducting metals and alloys

Electron beam machining

Melting and vapourisation

vacuum

A beam of an electron moving at high velocity

All material.

Laser beam machining

Melting and vapourisation

Normal atmosphere

A high power laser beam (Ruby rod)

All material.

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