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This section includes InterviewSolutions, each offering curated multiple-choice questions to sharpen your knowledge and support exam preparation. Choose a topic below to get started.

1.

State whether the following statement is true or false regarding the limitations of EP.(a) “In EP, base metal condition does not affect the process.”(b) True(c) FalseThis question was addressed to me at a job interview.The query is from EP-Applications and Limitations in section Chemical Processes of Advanced Machining

Answer»

The correct CHOICE is (B) True

For explanation: Base METAL condition affects the process of EP.

2.

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 mentionedThe question was asked in an interview for job.The origin of the question is EP-Process Parameters topic in portion Chemical Processes of Advanced Machining

Answer»

Correct choice is (d) All of the mentioned

Best explanation: Different work piece MATERIALS that can be machined using EP are carbon STEELS, stainless steels, COPPER, alpha brass, nickel, phosphor bronze, aluminium, MAGNESIUM etc.

3.

In the following terminals, part to be finished acts as which terminal in EP process?(a) Anode(b) Cathode(c) Neutral(d) None of the mentionedI have been asked this question in an interview.The above asked question is from Electro Polishing-Introduction topic in chapter Chemical Processes of Advanced Machining

Answer»

The correct option is (a) Anode

To elaborate: As this PROCESS is OPPOSITE to that of ELECTRO plating, PART to be finished is the anode in EP.

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 mentionedThe question was posed to me by my college director while I was bunking the class.The above asked question is from PCM-Process Description topic in chapter Chemical Processes of Advanced Machining

Answer» CORRECT answer is (b) Protection of surface against etching

To explain: In PCM, PHOTO TOOL is APPLIED as coating which act as stencil resist that PROTECT the surface from etching.
5.

Good surface quality and absence of burr eliminates which of the following?(a) Cutting operations(b) Finishing operations(c) Drilling operations(d) None of the mentionedI had been asked this question in an internship interview.I need to ask this question from CHM in chapter Chemical Processes of Advanced Machining

Answer» RIGHT answer is (d) None of the mentioned

Explanation: Absence of BURRS and good SURFACE quality eliminates finishing operations in CHM.
6.

State whether the following statement is true or false regarding the advantages of CHM.(a) “As there are no stresses induced, machining of delicate parts is possible.”(b) True(c) FalseThe question was posed to me in final exam.This is a very interesting question from CHM topic in section Chemical Processes of Advanced Machining

Answer»

Right ANSWER is (a) “As there are no stresses induced, machining of delicate parts is possible.”

The explanation: In CHM, no stresses are induced, which makes machining of delicate parts EASIER.

7.

What is the value of surface roughness, when special conditions are applied?(a) 0.001 – 0.025 µm(b) 0.025 – 0.05 µm(c) 0.05 – 0.075 µm(d) 0.075 – 0.1 µmI got this question at a job interview.I'd like to ask this question from CHM topic in portion Chemical Processes of Advanced Machining

Answer»

Correct answer is (b) 0.025 – 0.05 µm

To explain I would SAY: SURFACE ROUGHNESS OBTAINED when special CONDITIONS are applied, is between 0.025 – 0.05 µm.

8.

The process parameters will have direct impact on which of the following factors?(a) Etch factor(b) Machining rate(c) Production tolerance(d) All of the mentionedThe question was posed to me in a job interview.This key question is from CHM topic in division Chemical Processes of Advanced Machining

Answer»

The CORRECT answer is (d) All of the mentioned

To ELABORATE: All the FACTORS mentioned above, will have direct IMPACT due to above PROCESS parameters.

9.

Special coatings applied on work piece materials in order to protect them from chemical reaction are known as _________(a) Maskants(b) Protective coverings(c) Protective varnishing(d) None of the mentionedThis question was posed to me in unit test.The origin of the question is Chemical Milling topic in division Chemical Processes of Advanced Machining

Answer»

Right OPTION is (a) Maskants

To elaborate: The PROTECTIVE coatings on work PIECES are KNOWN as Maskants.

10.

State whether the following statement is true or false about etchants.(a) “Etchants are used for controlling H2 absorption in case of Ti alloys.”(b) True(c) FalseThe question was asked by my college professor while I was bunking the class.This interesting question is from CHM in chapter Chemical Processes of Advanced Machining

Answer»

The CORRECT OPTION is (a) “ETCHANTS are used for controlling H2 absorption in case of TI alloys.”

EXPLANATION: Etchants control the H2 absorption in Ti alloys.

11.

State whether the following statement is true or false regarding the applications of EP.(a) “Using Electropolishing, deburring and breaking sharp edges can be done.”(b) True(c) FalseI have been asked this question by my college professor while I was bunking the class.My query is from EP-Applications and Limitations topic in portion Chemical Processes of Advanced Machining

Answer»

The correct CHOICE is (a) “USING Electropolishing, DEBURRING and breaking sharp edges can be done.”

EASIEST explanation: Deburring and breaking sharp edges obtained from hand filing, grinding and HONING of tools.

12.

For machining of Cu material which of the following can be used as electrolytes?(a) H2PO4(b) H2PO4 and Na2CrO4(c) HCLO4(d) HNO3I had been asked this question in an online quiz.Origin of the question is EP-Process Parameters topic in division Chemical Processes of Advanced Machining

Answer»

The correct choice is (a) H2PO4

The BEST explanation: For CU material ELECTROLYTE used in EP PROCESS is H2PO4.

13.

Current density of the EP process generally varies between which of the following values?(a) 0.0001 – 0.001 A/cm^2(b) 0.005 – 1.8 A/cm^2(c) 1.9 – 2.532 A/cm^2(d) 3.523 – 4.23 A/cm^2This question was posed to me in quiz.My question is from EP-Process Parameters topic in chapter Chemical Processes of Advanced Machining

Answer»

The CORRECT answer is (B) 0.005 – 1.8 A/cm^2

The EXPLANATION: Generally current density VALUE used in EP process vary between 0.005 – 1.8 A/cm^2.

14.

What amount of current density can be used for Electropolishing to take place?(a) Very low(b) Low(c) Optimum(d) Very highI have been asked this question in an interview for job.I'm obligated to ask this question of Electro Polishing-Introduction topic in division Chemical Processes of Advanced Machining

Answer»

Right choice is (b) Low

For explanation I WOULD SAY: Limiting amount of current should be USED in EP process for anodic DISSOLUTION.

15.

State whether the following statement is true or false about applications of PCM.(a) “Using PCM, very high tempered materials are machined easily.”(b) True(c) FalseI had been asked this question in an interview.The above asked question is from PCM-Applications and Advantages topic in division Chemical Processes of Advanced Machining

Answer»

The correct OPTION is (a) “Using PCM, very high tempered materials are MACHINED easily.”

The best I can EXPLAIN: PCM can be favourable for very high tempered and brittle materials unlike that of traditional MACHINING, where they tend to break easily.

16.

How much amount of burr is produced, when components are machined using PCM?(a) Small(b) Medium(c) Large(d) No burrThis question was posed to me during an interview.The query is from PCM-Applications and Advantages in division Chemical Processes of Advanced Machining

Answer»

The correct CHOICE is (d) No burr

Easiest EXPLANATION: PHOTOCHEMICAL MILLING is a burr-free process i.e.., burr is not produced in this process.

17.

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 mentionedI had been asked this question in an interview.My question is based upon PCM-Process Description topic in division Chemical Processes of Advanced Machining

Answer»

Right OPTION is (B) Rinsing and drying

Best EXPLANATION: After etching is done in PCM, the parts are rinsed and DRIED.

18.

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 strippingThis question was addressed to me by my college director while I was bunking the class.My question is based upon PCM-Process Description in section Chemical Processes of Advanced Machining

Answer»

Correct CHOICE is (a) Generation of photographic FILM

Easiest explanation: Generation of photographic film USING CAD drawings is the first step in PCM.

19.

Photo chemical blanking can be used to machine the parts to high precision, up to which of the following thickness values?(a) 0.001 – 0.007 mm(b) 0.007 – 0.012 mm(c) 0.013 – 1.503 mm(d) 1.612 – 2.125 mmThe question was posed to me by my college director while I was bunking the class.Origin of the question is Photo Chemical Millling-Introduction topic in portion Chemical Processes of Advanced Machining

Answer» CORRECT answer is (c) 0.013 – 1.503 MM

Best explanation: PCB can be USED to machine PARTS of thickness 0.013 – 1.50 mm to high precision.
20.

Removal of sharp burrs come under which application of Chemical milling process?(a) Deep cuts(b) Multiple part machining(c) Improving surface characteristics(d) None of the mentionedThe question was asked during a job interview.My doubt stems from CHM-Applications topic in section Chemical Processes of Advanced Machining

Answer»

The correct ANSWER is (c) Improving surface characteristics

Explanation: REMOVAL of sharp burrs improve the surface characteristics of PARTS machined USING Chemical MILLING.

21.

Which of the following metals can be machined using the Chemical milling process?(a) Copper(b) Zinc(c) Steel(d) All of the mentionedThe question was asked by my college professor while I was bunking the class.My question is based upon CHM-Applications topic in section Chemical Processes of Advanced Machining

Answer»

Right CHOICE is (d) All of the mentioned

For explanation: Zinc, copper, LEAD, and NICKEL are some of the metals that can be chemically machined.

22.

Which of the following are the limitations of Chemical milling process?(a) Disposal of chemicals(b) Limited scribing accuracy(c) Surface imperfections(d) All of the mentionedI had been asked this question during an online interview.This interesting question is from CHM-Limitations in portion Chemical Processes of Advanced Machining

Answer»

The CORRECT choice is (d) All of the MENTIONED

The best explanation: All the factors mentioned above, are the LIMITATIONS of Chemical milling PROCESS.

23.

Castings having a larger grain size, will show how much surface roughness value?(a) Very low(b) Low(c) Medium(d) HighI had been asked this question in an interview for job.I'd like to ask this question from CHM topic in chapter Chemical Processes of Advanced Machining

Answer»

Right ANSWER is (d) High

The best EXPLANATION: In CASTINGS, as grain SIZE increases, surface roughness increases.

24.

State whether the following statement about Chemical milling is true or false.(a) “At higher temperatures, faster etching rates occur in Chemical milling.”(b) True(c) FalseThis question was posed to me in final exam.This is a very interesting question from Chemical Milling in portion Chemical Processes of Advanced Machining

Answer»

The correct ANSWER is (a) “At higher temperatures, faster etching rates OCCUR in Chemical milling.”

For explanation: As the temperature increases, reaction RATE increases which in TURN increases etching rate in CHM.

25.

Which of the following processes does not come under Chemical machining processes?(a) Chemical milling(b) Photo forming(c) Photo chemical filling(d) Photo chemical blankingThis question was posed to me in class test.The above asked question is from Photo Chemical Millling-Introduction in division Chemical Processes of Advanced Machining

Answer»

Right answer is (b) Photo FORMING

The EXPLANATION: Photo forming is a process of ELECTRO plating METALS over the mandrels which does not use chemical for MATERIAL removal.

26.

Hand masking, scribing and stripping can be difficult, due to which of the following factors?(a) Time consuming(b) Repetitive(c) Tedious(d) All of the mentionedThis question was addressed to me during an interview.Question is from CHM-Limitations topic in chapter Chemical Processes of Advanced Machining

Answer»

The correct choice is (d) All of the mentioned

For explanation I would say: All the factors mentioned above, are main DISADVANTAGES for different processes in CHM.

27.

Which of the following materials are excellent for Photochemical milling?(a) Brittle materials(b) Ductile materials(c) Elastic materials(d) None of the mentionedI had been asked this question during an interview.This is a very interesting question from PCM-Applications and Advantages topic in division Chemical Processes of Advanced Machining

Answer»

The correct option is (a) BRITTLE materials

Easiest explanation: Brittle materials are excellent candidates for PCM, SINCE they tend to break easily USING traditional MACHINING processes.

28.

In this method, which of the following techniques are used to apply the maskant on the machining surface?(a) Photographic techniques(b) Cut and peel masking(c) Silkscreen resist technique(d) None of the mentionedThis question was posed to me in a job interview.Asked question is from Photo Chemical Millling-Introduction topic in portion Chemical Processes of Advanced Machining

Answer»

Correct OPTION is (a) PHOTOGRAPHIC techniques

The best explanation: Maskant is applied on the MACHINING surface using photographic techniques in PCM.

29.

Which of the following are the other limitations of Chemical milling process?(a) Hydrogen pickup(b) Intergranular attack(c) Complex designs becoming expensive(d) All of the mentionedI had been asked this question in a national level competition.I'd like to ask this question from CHM-Limitations topic in section Chemical Processes of Advanced Machining

Answer»

Correct choice is (d) All of the mentioned

The best EXPLANATION: HYDROGEN pick up, intergranular ATTACK are some other LIMITATIONS in Chemical MILLING process.

30.

Which of the following materials have the highest machining rate and best surface quality?(a) Rolled metal sheets(b) Thick metal plates(c) Polymeric plates(d) Plastic sheetsThis question was posed to me in class test.The doubt is from CHM topic in portion Chemical Processes of Advanced Machining

Answer»

The correct answer is (a) ROLLED metal SHEETS

Easy EXPLANATION: Rolled metal sheets will have highest machining RATE and surface quality in CHM.

31.

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 mentionedThis question was posed to me during an online exam.Query is from EP-Applications and Limitations in section Chemical Processes of Advanced Machining

Answer»

Right OPTION is (d) All of the mentioned

To elaborate: Non-metallic inclusions, over pickling, large grain SIZE, direction ROLL MARKS, improper cold reduction leads to poor electro polishing.

32.

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 mentionedThis question was posed to me in an online interview.This intriguing question originated from Electro Polishing-Introduction topic in portion Chemical Processes of Advanced Machining

Answer»

Correct ANSWER is (c) All PROPERTIES

Explanation: The part machined USING EP process, possess true properties of the bulk MATERIAL.

33.

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 mentionedI have been asked this question during an interview.The doubt is from Electro Polishing-Introduction in portion Chemical Processes of Advanced Machining

Answer» RIGHT option is (C) Oxygen evolution

To EXPLAIN: If the current LEVEL increases beyond the limiting value, PITTING takes place due to gas evolution.
34.

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 mentionedThis question was addressed to me in quiz.My question is taken from Electro Polishing-Introduction in portion Chemical Processes of Advanced Machining

Answer»

Correct ANSWER is (C) All of them mentioned

For explanation: ELECTROLYTIC solution is a MIXTURE of several ACIDS and insoluble salts.

35.

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 mentionedThe question was asked during an online interview.Query is from PCM-Process Description in section Chemical Processes of Advanced Machining

Answer» RIGHT answer is (d) All of the mentioned

For explanation I would say: ETCHANT SELECTION depends on cost, quality, ETCH depth and MRR rate.
36.

What is the similarity between normal Chemical milling process and Photo chemical milling?(a) Both use chemicals(b) Maskant application method(c) None of the mentioned(d) All of the mentionedI got this question in homework.My question comes from Photo Chemical Millling-Introduction in portion Chemical Processes of Advanced Machining

Answer»

The correct CHOICE is (a) Both USE chemicals

Explanation: Both METHOD are similar in ONE PROPERTY i.e.., they both use chemicals.

37.

Which of the tolerance values are obtained, when we use cut and peel mask method for maskant?(a) ± 0.013 mm(b) ± 0.045 mm(c) ± 0.077 mm(d) ± 0.179 mmThe question was posed to me by my school teacher while I was bunking the class.Asked question is from CHM in division Chemical Processes of Advanced Machining

Answer»

Correct option is (d) ± 0.179 MM

To explain: TOLERANCE VALUE of ± 0.179 mm, will be obtained, when we use CUT and PEEL mask method.

38.

In Chemical milling, excessive flow of chemical reagent results in which of the following defects?(a) Channellings(b) Grooves(c) Ridges(d) All of the mentionedI got this question by my college director while I was bunking the class.Asked question is from Chemical Milling in portion Chemical Processes of Advanced Machining

Answer»

Correct ANSWER is (d) All of the mentioned

For explanation: In CHEMICAL milling, if the REAGENT FLOWS excessively, then the defects mentioned above may OCCUR.

39.

CHM cannot eliminate which of the following defects?(a) Irregularities and dents(b) Surface scratches(c) Waviness(d) All of the mentionedThis question was addressed to me in a national level competition.Question is from Chemical Milling in section Chemical Processes of Advanced Machining

Answer»

Correct answer is (d) All of the mentioned

Explanation: CHM is not a FINISHING process as that of MAF, there are some SORT of DEFECTS in Chemical milling.

40.

Electropolishing cannot cover up which type of defects?(a) Burrs on surfaces(b) Scales and distortions(c) Non-metallic inclusions(d) Metallographic examinationThe question was asked during an online exam.Enquiry is from EP-Applications and Limitations topic in division Chemical Processes of Advanced Machining

Answer»

The CORRECT OPTION is (c) Non-metallic inclusions

The best EXPLANATION: SEAMS and non-metallic inclusions are some defects which cannot be covered up USING EP.

41.

Which of the following come under process parameters of Chemical milling?(a) Reagent type(b) Concentration(c) Operating temperature(d) All of the mentionedThe question was posed to me during an interview.Enquiry is from CHM in chapter Chemical Processes of Advanced Machining

Answer» RIGHT OPTION is (d) All of the MENTIONED

To explain I would SAY: All the parameters mentioned above, are different process parameters required for Chemical milling.
42.

State whether the following statement is true or false regarding process parameters of EP.(a) “In EP, process parameters have a direct impact on surface quality and productivity of process.”(b) True(c) FalseI got this question in quiz.My doubt is from EP-Process Parameters in portion Chemical Processes of Advanced Machining

Answer»

Right option is (a) “In EP, PROCESS parameters have a direct IMPACT on SURFACE QUALITY and PRODUCTIVITY of process.”

The best explanation: In Electropolishing, parameters have a direct impact on quality of surface and productivity.

43.

Porous castings yield, which type of surfaces in Chemical milling process?(a) Uniform surfaces(b) Even surfaces(c) Uneven surfaces(d) None of the mentionedI have been asked this question during an interview for a job.I'd like to ask this question from CHM-Limitations in section Chemical Processes of Advanced Machining

Answer»

The correct choice is (C) Uneven SURFACES

Easiest explanation: As there are porous castings, there would be pores on the SURFACE which lead to uneven surfaces.

44.

Which type of etching rate, mentioned below, produces low surface roughness?(a) Very low(b) Low(c) Medium(d) HighThis question was addressed to me in my homework.My question is based upon CHM in section Chemical Processes of Advanced Machining

Answer»

Correct answer is (d) High

To explain: In Chemical MILLING, high ETCHING RATE PRODUCES low surface roughness values and tolerances.

45.

State whether the following statement is true or false about Chemical milling.(a) “CHM can also affect mechanical properties, if they differ from surface layer to base metal.”(b) True(c) FalseI got this question in an online quiz.My doubt is from CHM in section Chemical Processes of Advanced Machining

Answer»

Right choice is (a) “CHM can also affect mechanical PROPERTIES, if they DIFFER from surface layer to base metal.”

Best explanation: CHEMICAL MILLING can affect the mechanical properties of the machined parts if they are DIFFERENT at surface layers and base metal.

46.

Which of the tolerance values are obtained, when we use silk-screen resist method for maskant?(a) ± 0.013 mm(b) ± 0.045 mm(c) ± 0.077 mm(d) ± 0.179 mmI have been asked this question in unit test.The query is from CHM topic in division Chemical Processes of Advanced Machining

Answer»

Correct answer is (c) ± 0.077 MM

The best I can explain: TOLERANCE value of ± 0.077 mm, will be OBTAINED, when we use SILK screen resist method.

47.

Which of the following can be used to apply the maskants on work piece in Chemical milling?(a) Dipping or spraying(b) Rolling or electro coating(c) Adhesive tapes(d) All of the mentionedI had been asked this question in a job interview.This key question is from CHM in division Chemical Processes of Advanced Machining

Answer»

The CORRECT CHOICE is (d) All of the mentioned

To elaborate: MASKANTS can be APPLIED to WORK piece, by the above mentioned means.

48.

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 mentionedI got this question in an internship interview.I'm obligated to ask this question of PCM-Applications and Advantages in portion Chemical Processes of Advanced Machining

Answer» RIGHT OPTION is (d) All of the MENTIONED

For explanation: Using PCM, the above mentioned APPLICATIONS can be FULFILLED.
49.

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 mentionedI have been asked this question at a job interview.My doubt is from PCM-Applications and Advantages topic in section Chemical Processes of Advanced Machining

Answer»

Right option is (c) Flat surfaces

The best EXPLANATION: The work pieces MUST be flat in ORDER to carry on the PCM process.

50.

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 mentionedThe question was asked by my college director while I was bunking the class.My query is from PCM-Applications and Advantages in division Chemical Processes of Advanced Machining

Answer» RIGHT choice is (a) Low

The explanation is: RELATIVELY low COST per UNIT is required in PCM, since tooling is inexpensive compared to that of traditional PRACTICES.