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51.

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 mentionedThis question was addressed to me in a national level competition.This intriguing question originated from PCM-Process Description in division Chemical Processes of Advanced Machining

Answer»

The correct OPTION is (d) All of the mentioned

Explanation: The PROTECTIVE layers are REMOVED by the use of CHEMICALS and by using mechanical techniques with chemicals.

52.

What is the other name for photographic film generated in Photochemical milling?(a) Photo mask(b) Photo tool(c) Photo cover(d) Photo plateThe question was posed to me during an interview.I'd like to ask this question from PCM-Process Description in section Chemical Processes of Advanced Machining

Answer» RIGHT choice is (B) Photo tool

The BEST I can explain: The PHOTOGRAPHIC film generated USING CAD drawings, which is also called as Photo tool.
53.

State whether the following statement is true or false regarding Photochemical milling.(a) “Unlike that of CHM, PCM can also be used to create parts.”(b) True(c) FalseI got this question at a job interview.The query is from Photo Chemical Millling-Introduction in chapter Chemical Processes of Advanced Machining

Answer»

The correct option is (a) “UNLIKE that of CHM, PCM can also be USED to create parts.”

EASIEST explanation: In CHM original parts manufactured in other PROCESSES are machined. Unlike that case, in PCM parts can be created from thin sheets using MASKANTS.

54.

Which of the following is the most popular application for weight reduction of aerospace components?(a) Shallow cuts(b) Deep cuts(c) Very deep cuts(d) None of the mentionedI had been asked this question in an interview.The above asked question is from CHM-Applications in chapter Chemical Processes of Advanced Machining

Answer»

The correct option is (a) Shallow cuts

The BEST I can EXPLAIN: Shallow cuts in large thin SHEETS helps in reducing the weight, especially in AEROSPACE INDUSTRIES.

55.

What is the value of surface roughness, which is generally obtained using Chemical milling?(a) 0.01 – 0.08 µm(b) 0.1 – 0.8 µm(c) 1 – 8 µm(d) 10 – 80 µmI have been asked this question in a job interview.My question comes from CHM topic in section Chemical Processes of Advanced Machining

Answer»

The correct option is (B) 0.1 – 0.8 µm

The best explanation: Surface roughness OBTAINED when general CONDITIONS are APPLIED, is between 0.1 – 0.8 µm.

56.

Which of the following is not a limitation of Chemical milling process?(a) Steep tapers not practical(b) Low scrap rates(c) Less scribing accuracy(d) Deep narrow cutsThe question was posed to me in an interview for job.The above asked question is from CHM-Limitations topic in portion Chemical Processes of Advanced Machining

Answer» RIGHT ANSWER is (b) LOW scrap RATES

Explanation: Low scrap rates are possible in Chemical milling, which is an advantage to the process.
57.

What are the tolerance values achieved in Chemical milling, which depend on work piece material and depth of cut?(a) ± 10%(b) ± 20%(c) ± 30%(d) ± 40%The question was posed to me during an interview for a job.My question is taken from CHM topic in section Chemical Processes of Advanced Machining

Answer»

Correct CHOICE is (a) ± 10%

Best explanation: TOLERANCES of ± 10% of CUT width are achieved using CHM.

58.

Scribing plates are used to define, which of the following parameters in Chemical milling?(a) Areas to be exposed(b) Volumes to be exposed(c) Areas not to be exposed(d) Volumes not to be exposedI got this question during an online exam.My doubt is from CHM in section Chemical Processes of Advanced Machining

Answer»

Right answer is (a) AREAS to be exposed

To explain I would SAY: SCRIBING PLATES DEFINES the areas that are to be exposed for removal of material.

59.

In maskant application, photo-resist masks ensure which of the following advantages?(a) High accuracy(b) Ease of repetition(c) Ease of modification(d) All of the mentionedThe question was posed to me in unit test.I'm obligated to ask this question of CHM topic in chapter Chemical Processes of Advanced Machining

Answer»

Correct answer is (d) All of the MENTIONED

To explain I would SAY: We will have the ADVANTAGES which are mentioned above, if we use photo RESIST masking.

60.

Which of the following solutions cannot be used as chemical reactive solution in CHM?(a) Acidic solution(b) Alkaline solution(c) Neutral solution(d) None of the mentionedThis question was posed to me in my homework.Asked question is from Chemical Milling topic in section Chemical Processes of Advanced Machining

Answer»

Right option is (C) NEUTRAL solution

To explain I would SAY: Both acidic or alkane solutions are used for chemical dissolution in Chemical milling.

61.

Metals containing which of the following chemicals will be troublesome in EP process?(a) Silicon(b) Lead(c) Sulphur(d) All of them mentionedThis question was posed to me in quiz.Query is from EP-Applications and Limitations in division Chemical Processes of Advanced Machining

Answer»

Right CHOICE is (d) All of them mentioned

For EXPLANATION I WOULD SAY: All the elements mentioned above, if PRESENT in metals, will be troublesome in EP process.

62.

Electropolishing removes scales and distortions that are produces by which of the processes below?(a) Annealing(b) Nitriding(c) Carburizing(d) All of the mentionedThe question was asked by my college professor while I was bunking the class.My doubt stems from EP-Applications and Limitations topic in chapter Chemical Processes of Advanced Machining

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

Explanation: SCALES and distortions produced by annealing, CARBURIZING, NITRIDING, welding and soldering can be removed using EP.
63.

Electropolishing prepares surfaces for which of the following processes?(a) Electron Beam machining(b) Electro plating(c) Laser beam machining(d) Magnetic Abrasive machiningI had been asked this question by my college director while I was bunking the class.My query is from EP-Applications and Limitations topic in section Chemical Processes of Advanced Machining

Answer»

Correct option is (B) Electro plating

To explain: EP prepares surfaces for electroplating, which CREATES an opportunity for BEST ADHERENCE.

64.

State whether the following statement is true or false regarding advantages of PCM.(a) “In PCM, lead times are large, when compared to that required for hard tooling using traditional means.”(b) True(c) FalseI had been asked this question by my college director while I was bunking the class.Enquiry is from PCM-Applications and Advantages topic in division Chemical Processes of Advanced Machining

Answer»

The correct answer is (B) True

The explanation is: LEAD times are small when compared to that required by PROCESSES that require HARD tooling.

65.

In case of photochemical milling that use using lettering and graphics for surface etching, what will be the depth of surface etched?(a) Very deep(b) Up to certain depth(c) Half-way(d) None of the mentionedThe question was posed to me in a job interview.This intriguing question comes from Photo Chemical Millling-Introduction in chapter Chemical Processes of Advanced Machining

Answer»

Right answer is (B) Up to CERTAIN depth

Explanation: Sometimes photochemical MACHINING is used to surface-etch components with lettering or graphics, in which ETCHANT works to only a certain depth.

66.

What is the value of shallow cuts obtained on sheets and plates, when we use CHM?(a) 3.83 mm(b) 6.39 mm(c) 12.27 mm(d) 20.32 mmThe question was posed to me in an online quiz.Query is from CHM-Limitations in chapter Chemical Processes of Advanced Machining

Answer» RIGHT ANSWER is (C) 12.27 mm

Explanation: Very shallow depths of VALUE 12.27 mm, are obtained when we USE CHM.
67.

State whether the following statement is true or false regarding the applications of CHM.(a) “Removal of thin surfaces, prior to inspection, is done for detection of hidden defects.”(b) True(c) FalseThis question was posed to me in an interview for job.Asked question is from CHM-Applications in section Chemical Processes of Advanced Machining

Answer»

Correct option is (a) “Removal of thin surfaces, prior to inspection, is done for DETECTION of HIDDEN defects.”

The BEST I can explain: Removal of thin surfaces is done to detect the hidden defects in surfaces USING CHM.

68.

Which type of taper can be achieved, using Chemical milling, on contours?(a) Discontinuous(b) Continuous(c) Periodic(d) None of the mentionedThis question was posed to me by my college professor while I was bunking the class.This interesting question is from CHM in section Chemical Processes of Advanced Machining

Answer»

The correct OPTION is (b) Continuous

Best explanation: USING CHEMICAL milling, a continuous TAPER, on CONTOURS can be achieved.

69.

State whether the following statement is true or false regarding the advantages?(a) “Capital cost of equipment, for machining large components, is relatively high.”(b) True(c) FalseThe question was posed to me in an online interview.I'd like to ask this question from CHM topic in portion Chemical Processes of Advanced Machining

Answer»

Right choice is (B) True

To explain I would say: Capital COST of equipment, is RELATIVELY low for machining large components.

70.

For what value of machining depths, surface roughness sharply increases with depth of cut?(a)

Answer»

The CORRECT choice is (b) <200 µm

Easy explanation: For MATERIAL depths <200 µm, surface ROUGHNESS increases with depth of CUT.

71.

State whether the following statement is true or false regarding MRR.(a) “The rate of material removal, does not depend on uniformity of the solution temperature.”(b) True(c) FalseI had been asked this question in unit test.This key question is from CHM topic in portion Chemical Processes of Advanced Machining

Answer»

Right answer is (B) True

The EXPLANATION: Material removal RATE ALSO depends on UNIFORMITY of the solution temperature.

72.

Which of the tolerance values are obtained, when we use photo resist method for maskant application?(a) ± 0.013 mm(b) ± 0.045 mm(c) ± 0.077 mm(d) ± 0.179 mmI got this question in final exam.My question is taken from CHM topic in portion Chemical Processes of Advanced Machining

Answer» CORRECT OPTION is (a) ± 0.013 MM

Best explanation: Tolerance VALUE of ± 0.013 mm, will be obtained, when we use photo resist method.
73.

Pre cleaning is done on the work piece surface in order to achieve, which of the following factors?(a) To provide good adhesion(b) To provide clean surface(c) To assure the absence of contaminants(d) All of the mentionedThe question was posed to me by my college director while I was bunking the class.This interesting question is from Chemical Milling in portion Chemical Processes of Advanced Machining

Answer»

The CORRECT CHOICE is (d) All of the mentioned

The best I can EXPLAIN: All the FACTORS mentioned above, are ACHIEVED thorough pre-cleaning process.

74.

Which of the following is a limitation of EP process?(a) Rough scratches removal(b) Scales removal(c) Distortions removal(d) Burr removalThe question was posed to me during an internship interview.My question comes from EP-Applications and Limitations in chapter Chemical Processes of Advanced Machining

Answer»

The correct option is (a) Rough SCRATCHES removal

To EXPLAIN: In EP, rough scratches cannot be REMOVED even by considerable amount of process.

75.

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 mentionedI have been asked this question in a job interview.I want to ask this question from EP-Applications and Limitations in portion Chemical Processes of Advanced Machining

Answer»

The correct OPTION is (a) Cold ROLLED metals

Best explanation: Cold rolled metals are the most IMPORTANT MATERIALS for ECONOMICAL and high quality polishing.

76.

For harder materials, which of the following etching rates are obtained?(a) Very low(b) Low(c) Medium(d) HighThe question was posed to me in a national level competition.Origin of the question is CHM in section Chemical Processes of Advanced Machining

Answer» RIGHT answer is (d) High

For EXPLANATION: In Chemical MILLING, harder materials need HIGHER etching rates.
77.

State whether the following statement is true or false regarding maskants.(a) “After etching, maskants should be removed easily and inexpensively.”(b) True(c) FalseThis question was addressed to me in semester exam.This intriguing question originated from CHM topic in division Chemical Processes of Advanced Machining

Answer»

The CORRECT CHOICE is (a) “After etching, maskants should be removed easily and INEXPENSIVELY.”

EXPLANATION: After etching is done, maskants should be removed easily by inexpensive means.

78.

What is the range, between which, the depth of cut in Chemical milling varies?(a) 0.13 – 0. 84 mm(b) 0.93 – 1.56 mm(c) 2.54 – 12.27 mm(d) 13.3 – 104.56 mmThis question was posed to me in unit test.Question is from CHM-Applications topic in division Chemical Processes of Advanced Machining

Answer»

The correct CHOICE is (C) 2.54 – 12.27 MM

Easiest EXPLANATION: Practically, depth of CUT in Chemical milling range between 2.54 – 12.27 mm.

79.

By using Chemical machining, which of the following can be produced?(a) Pockets(b) Contours(c) Slots(d) All of the mentionedI had been asked this question in an online quiz.Query is from Chemical Milling topic in section Chemical Processes of Advanced Machining

Answer»

The correct choice is (d) All of the mentioned

Easy explanation: By the USE of CHM, POCKETS, contours, SLOTS and MATERIALS having high STRENGTH to weight ratio can be machined.

80.

Which of the following are the tools required for Chemical milling?(a) Maskants(b) Etchants(c) Scribing plates(d) All of the mentionedThis question was posed to me in class test.Asked question is from CHM in division Chemical Processes of Advanced Machining

Answer»

Correct choice is (d) All of the MENTIONED

To EXPLAIN: All the components mentioned above, are required to carry out CHEMICAL milling PROCESS.

81.

What is the electrolytic solution’s temperature when stainless steel is machined?(a) 50^o C(b) 80^o C(c) 120^o C(d) 150^o CI had been asked this question in class test.Asked question is from EP-Process Parameters topic in portion Chemical Processes of Advanced Machining

Answer» CORRECT option is (b) 80^o C

Best EXPLANATION: Temperature of electrolytic SOLUTION used for machining STAINLESS steel is 80^o C.
82.

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 mentionedI have been asked this question in class test.I need to ask this question from EP-Process Parameters in division Chemical Processes of Advanced Machining

Answer»

The correct OPTION is (d) All of the mentioned

To elaborate: The process parameters of Electropolishing include current density, applied voltage, ACID type, temperature original SURFACE roughness, work piece condition and material.

83.

State whether the following statement is true or false regarding EP process.(a) “Electropolishing is same as electro plating.”(b) True(c) FalseThe question was asked in a job interview.This intriguing question comes from Electro Polishing-Introduction topic in chapter Chemical Processes of Advanced Machining

Answer»

The correct ANSWER is (B) True

The EXPLANATION: ELECTROPOLISHING is the OPPOSITE of electroplating.

84.

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 mentionedI have been asked this question by my college director while I was bunking the class.Query is from PCM-Applications and Advantages in chapter Chemical Processes of Advanced Machining

Answer»

The correct ANSWER is (d) None of the mentioned

Explanation: In PCM, MATERIAL properties such as HARDNESS, ductility and GRAIN structure are not changed.

85.

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 mentionedThe question was asked in a job interview.This interesting question is from PCM-Applications and Advantages in portion Chemical Processes of Advanced Machining

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

Best explanation: Typical components such as gaskets, lead FRAMES, contacts, CONNECTORS, probes, filters and screens can be machined using PCM.
86.

What are the values of scrap rates obtained in Chemical milling?(a) 1%(b) 3%(c) 5%(d) 7%The question was asked by my college director while I was bunking the class.Enquiry is from CHM in portion Chemical Processes of Advanced Machining

Answer»

Right answer is (b) 3%

To explain I WOULD say: Low SCRAPES rates AROUND 3% are obtained when we use the Chemical milling PROCESS.

87.

Which of the following defects cannot be altered or eliminated using CHM?(a) Waviness(b) Surface imperfections(c) Scratches(d) DentsI got this question by my school principal while I was bunking the class.My doubt stems from CHM in chapter Chemical Processes of Advanced Machining

Answer»

The CORRECT answer is (b) SURFACE imperfections

The EXPLANATION is: Using CHM, surface imperfections cannot be ELIMINATED.

88.

To machine high quality parts using CHM, which of the following need not be necessary?(a) Heat treatment of work piece(b) Grain size of work piece(c) Frequency of vibrations(d) Range of work piecesThe question was posed to me during a job interview.My question is from CHM in portion Chemical Processes of Advanced Machining

Answer» RIGHT OPTION is (c) FREQUENCY of vibrations

Explanation: To MACHINE high qualities products vibrational frequency is not NECESSARY in CHM.
89.

State whether the following statement is true or false about etching rates.(a) “As the etching rate increases, low surface roughness values occur.”(b) True(c) FalseI had been asked this question in my homework.This interesting question is from CHM topic in portion Chemical Processes of Advanced Machining

Answer» RIGHT answer is (a) “As the etching rate INCREASES, low SURFACE roughness values OCCUR.”

Easiest explanation: High etching rates result in low surface roughness values.
90.

State which of the following statement is true or false regarding Chemical milling.(a) “Maskants are generally used in CHM, to protect the work piece from the etching chemical agent.”(b) True(c) FalseThis question was posed to me in an interview.Asked question is from CHM in portion Chemical Processes of Advanced Machining

Answer»

Correct ANSWER is (a) “MASKANTS are generally used in CHM, to protect the work piece from the ETCHING chemical agent.”

For explanation: In CHM, maskants are used to protect the work piece from chemical agents.

91.

Which of the following, are the general materials used for maskant application?(a) Neoprene(b) Poly vinyl chloride(c) Polyethylene(d) All of the mentionedI got this question in a national level competition.This is a very interesting question from CHM topic in chapter Chemical Processes of Advanced Machining

Answer»

Right answer is (d) All of the mentioned

Best EXPLANATION: All the materials mentioned above, can be used as MASKANT materials.

92.

During Chemical milling, depth of etch is controlled by which factor of immersion?(a) Time(b) Mask method(c) Mask area(d) None of the mentionedThis question was addressed to me in my homework.My doubt is from Chemical Milling in portion Chemical Processes of Advanced Machining

Answer» RIGHT OPTION is (a) Time

For explanation I would SAY: As the immersion time increases, DEPTH of the ETCHING increases.
93.

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 mentionedThe question was asked in an internship interview.I want to ask this question from EP-Applications and Limitations in section Chemical Processes of Advanced Machining

Answer»

Correct ANSWER is (d) All of the mentioned

Best explanation: Polishing LIGHT fixtures of electrical conduits, OUTLET BOXES, and medical, surgical, and food PROCESSING equipment.

94.

In the following types of voltage, which one best suites EP process?(a) Randomly Fluctuating(b) Constant(c) Periodically fluctuating(d) None of the mentionedI had been asked this question during a job interview.Question is taken from EP-Process Parameters topic in section Chemical Processes of Advanced Machining

Answer»

Right choice is (b) CONSTANT

The BEST I can EXPLAIN: For the machining to TAKE place in Electropolishing PROCESS, voltage should be correct and constant.

95.

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 mentionedI had been asked this question by my college director while I was bunking the class.The question is from PCM-Process Description topic in section Chemical Processes of Advanced Machining

Answer»

Correct answer is (b) ULTRAVIOLET source

The explanation is: Ultraviolet light SOURCES are USED to transfer the image of the REQUIRED geometry on to the resist, precisely.

96.

In some cases, Photochemical milling can also be called as ______________(a) Photo chemical blasting(b) Photo chemical blanking(c) Photo chemical drilling(d) Photo chemical erosionThis question was addressed to me in a job interview.This interesting question is from Photo Chemical Millling-Introduction topic in chapter Chemical Processes of Advanced Machining

Answer»

The CORRECT answer is (B) PHOTO chemical blanking

The best explanation: In some CASES flat, thin gauge complex parts can be MACHINED, this process is known as Photochemical Blanking (PCB).

97.

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 mentionedThe question was posed to me during an internship interview.The query is from PCM-Process Description topic in portion Chemical Processes of Advanced Machining

Answer»

Right choice is (d) All of the mentioned

Easy EXPLANATION: After GENERATION of photo-tool, it is applied to the CHEMICALLY CLEANED work SURFACE.

98.

How many designs can be machined from the same sheet in Chemical milling?(a) Only one(b) Two(c) Three(d) MultipleI had been asked this question in semester exam.My doubt is from CHM-Applications in section Chemical Processes of Advanced Machining

Answer»

Correct OPTION is (d) Multiple

Easy explanation: In Chemical milling, multiple designs can b machined on a LARGE thin sheet DEPENDING upon the size of the designs.

99.

Which of the following non-metallic materials can be machined using the Chemical milling process?(a) Plastics(b) Glass(c) Ceramics(d) All of the mentionedThe question was asked in final exam.My enquiry is from CHM-Applications in section Chemical Processes of Advanced Machining

Answer»

The correct answer is (d) All of the mentioned

For explanation: Non-metallic materials such as glass, CERAMICS and plastics can ALSO be MACHINED using Chemical milling PROCESS.

100.

Which of the following, are the other advantages of CHM?(a) Design changes(b) Less skilled operator(c) Minor tooling costs(d) All of the mentionedThe question was posed to me in a job interview.This interesting question is from CHM topic in portion Chemical Processes of Advanced Machining

Answer» CORRECT choice is (d) All of the mentioned

To explain I WOULD say: All of the advantages mentioned above, are OBTAINED using CHM.