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51.

What are the values of current densities used in ECDB process?(a) 1 – 5 A/cm^2(b) 5 – 10 A/cm^2(c) 10 – 15 A/cm^2(d) 15 – 20 A/cm^2I have been asked this question in my homework.Question is taken from Electrochemical Deburring in portion Electrochemical Processes of Advanced Machining

Answer»

Correct CHOICE is (b) 5 – 10 A/cm^2

The explanation is: Current densities used in ECDB PROCESS range between 5 – 10 A/cm^2.

52.

In advanced machining processes, full form of ECDB is _________(a) Electrochemical Drill buffing(b) Electrochemical Dimension Breaking(c) Electrochemical Deburring(d) Electrochemical DimensioningI had been asked this question in a job interview.This interesting question is from Electrochemical Deburring topic in section Electrochemical Processes of Advanced Machining

Answer»

Correct option is (c) Electrochemical DEBURRING

The EXPLANATION: In ADVANCED machining processes, FULL form of ECDB is Electrochemical Deburring.

53.

What are the values of tapers produced in Electrochemical jet drilling process?(a) 1 to 2 included angles(b) 5 to 10 included angles(c) 10 to 15 included angles(d) 20 to 30 included anglesThis question was addressed to me during a job interview.Question is from Electrochemical Jet Drilling in section Electrochemical Processes of Advanced Machining

Answer» RIGHT answer is (b) 5 to 10 included ANGLES

The best I can explain: In Electrochemical jet DRILLING tapers produced are about 5 to 10 included angles.
54.

What is the value of the ratio of hole diameter to capillary diameter in ECJD?(a) 2(b) 4(c) 6(d) 8I got this question during an online exam.This is a very interesting question from Electrochemical Jet Drilling in chapter Electrochemical Processes of Advanced Machining

Answer» CORRECT option is (a) 2

Easy explanation: Generally, RATIO of hole DIAMETER to CAPILLARY diameter in ECJD is 2.
55.

Compared to the diameter of the electrolyte jet, how are the produced hole diameters?(a) 2 times(b) 3 times(c) 4 times(d) 5 timesThis question was addressed to me during an interview.This is a very interesting question from Electrochemical Jet Drilling in chapter Electrochemical Processes of Advanced Machining

Answer»

Right answer is (c) 4 times

For explanation: In ECJD, the holes PRODUCED are nearly 4 times that of the ELECTROLYTE JET diameter used in the process.

56.

What is the value of diameter-to-depth ratio obtained using ECJD process?(a) 1:10(b) 2:25(c) 1:12(d) 1:100The question was asked in an online interview.The above asked question is from Electrochemical Jet Drilling topic in portion Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (c) 1:12

The explanation is: Electrochemical JET drilling is the process USED for producing fine holes, having DIAMETER to DEPTH ratio of 1:12.

57.

What is the value of pressure of electrolyte used in ECDB process?(a) 0.1 to 0.2 MPa(b) 0.3 to 0.5 MPa(c) 0.7 to 0.9 MPa(d) 1.1 to 1.5 MPaThe question was asked in a national level competition.I'm obligated to ask this question of Electrochemical Deburring in chapter Electrochemical Processes of Advanced Machining

Answer»

Right CHOICE is (b) 0.3 to 0.5 MPa

To explain: PRESSURE of ELECTROLYTE used in ECDB is maintained between 0.3 to 0.5 MPa.

58.

How many holes can be drilled simultaneously using ES drilling process?(a) One hole(b) Two holes(c) Three holes(d) Multiple holesThis question was posed to me by my college director while I was bunking the class.The question is from Electrostream (Capillary) Drilling in section Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (d) Multiple holes

The EXPLANATION: DEPENDING upon the size of diameters, multiple holes can be drilled using ES DRILLING.

59.

Which of the following can be used as electrolytes in STEM process?(a) Sulphuric acid(b) Nitric acid(c) Hydrochloric acids(d) All of the mentionedThis question was addressed to me in exam.Enquiry is from Shaped Tube Electrolytic Machining topic in section Electrochemical Processes of Advanced Machining

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

To ELABORATE: Electrolytes used in STEM are sulphuric ACID, nitric acid and HYDROCHLORIC acids.
60.

What happens to the electrolyte conductivity if the gap increases, in ECDR?(a) Increases(b) Decreases(c) Remains same(d) None of the mentionedI have been asked this question in examination.This key question is from Electro Chemical Drilling in section Electrochemical Processes of Advanced Machining

Answer»

The CORRECT ANSWER is (a) INCREASES

Explanation: In ECDR, as the gap increases, the ELECTRICAL CONDUCTIVITY increases and the dissolution of material increases.

61.

What is the value of diameter of glass nozzle used in Electrostream drilling?(a) 0.01 – 0.02 mm(b) 0.025 – 0.5 mm(c) 0.5 – 0.75 mm(d) 0.75 – 1.25 mmThe question was posed to me during an internship interview.Query is from Electrostream (Capillary) Drilling in portion Electrochemical Processes of Advanced Machining

Answer»

The CORRECT choice is (b) 0.025 – 0.5 mm

Explanation: ELECTROSTREAM DRILLING uses a gas nozzle, whose DIAMETER RANGES between 0.025 – 0.5 mm.

62.

How much part of tool needs to be in contact with work piece for removal of material?(a) Quarter(b) Half(c) Full(d) No contactI have been asked this question in semester exam.I'm obligated to ask this question of Electrochemical Jet Drilling topic in chapter Electrochemical Processes of Advanced Machining

Answer»

Correct option is (d) No contact

The explanation: As this is an electrochemical dissolution process, ELECTRODES should not be in contact in ORDER to AVOID SPARKING.

63.

For high machining accuracy and smaller diametrical oversize, which type of feed rates are required?(a) Very low(b) Low(c) Medium(d) HighI have been asked this question during an interview.This is a very interesting question from Electro Chemical Drilling in portion Electrochemical Processes of Advanced Machining

Answer» CORRECT answer is (d) HIGH

The explanation: High feed rates are RECOMMENDED for smaller DIAMETRICAL oversize and more ACCURACY.
64.

In advanced machining processes, what is the full form of ECJD?(a) Electrochemical Jet Dimensioning(b) Electrochemical Jet Drilling(c) Electrical Jet Drilling(d) Electrical Jet DimensioningI had been asked this question in an online interview.I want to ask this question from Electrochemical Jet Drilling topic in portion Electrochemical Processes of Advanced Machining

Answer»

The correct answer is (B) ELECTROCHEMICAL Jet DRILLING

Explanation: In advanced MACHINING processes, full form of ECJD is Electrochemical Jet Drilling.

65.

What happens to the overcut size, if we use the electrolyte flow mode under backward pressure?(a) Decreases(b) Increases(c) Increase and then decrease(d) None of the mentionedThis question was posed to me in an international level competition.The above asked question is from Electro Chemical Drilling in section Electrochemical Processes of Advanced Machining

Answer»

Correct choice is (a) Decreases

To EXPLAIN: If we USE backward PRESSURE for electrolyte FLOW, the overcut size decreases.

66.

What are the values of electrolyte pressure recommended for ES drilling?(a) 50 – 100 kPa(b) 100 – 250 kPa(c) 275 – 400 kPa(d) 500 – 750 kPaI had been asked this question in an online interview.I would like to ask this question from Electrostream (Capillary) Drilling topic in portion Electrochemical Processes of Advanced Machining

Answer»

Right choice is (C) 275 – 400 kPa

To explain I WOULD say: Electrolyte PRESSURE values must range between 275 – 400 kPa for ES drilling to TAKE place.

67.

Which of the following electrolyte can be used for deburring process in ECDB?(a) NaNO2(b) NaNO3(c) NaCl(d) All of the mentionedThis question was posed to me in examination.Question is taken from Electrochemical Deburring topic in chapter Electrochemical Processes of Advanced Machining

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

Explanation: Sodium NITRITE, sodium nitrate and sodium chloride are the electrolytes used in ECDB PROCESS.
68.

What are the values of voltages used in ES drilling process?(a) 10 to 40 V(b) 40 to 70 V(c) 70 to 150 V(d) 150 to 300 VThis question was posed to me by my college director while I was bunking the class.I need to ask this question from Electrostream (Capillary) Drilling in portion Electrochemical Processes of Advanced Machining

Answer»

Right answer is (c) 70 to 150 V

Easiest EXPLANATION: VOLTAGE values used in ES drilling, range between 70 to 150 V.

69.

What is the concentration of electrolytes that are commonly used in ES drilling?(a) 1 to 10wt %(b) 12 to 20wt %(c) 23 to 30wt %(d) 34 to 50wt %The question was posed to me during an interview.My doubt stems from Electrostream (Capillary) Drilling in division Electrochemical Processes of Advanced Machining

Answer» RIGHT choice is (B) 12 to 20wt %

Explanation: Commonly USED electrolytes have a concentration between 12 to 20wt %.
70.

What are the values of pressures used for electrolyte in STEM?(a) 10 – 100 kPa(b) 150 – 250 kPa(c) 275 – 500 kPa(d) 600 – 750 kPaThe question was asked in semester exam.Asked question is from Shaped Tube Electrolytic Machining in division Electrochemical Processes of Advanced Machining

Answer»

Correct answer is (C) 275 – 500 KPA

The explanation is: Values of PRESSURE used in the STEM PROCESS, range between 275 – 500 kPa.

71.

What are the limitations of STEM process?(a) Used for corrosion resistant materials(b) Hazardous waste is generated(c) Complex machining and tooling systems(d) All of the mentionedThe question was asked by my school principal while I was bunking the class.I'm obligated to ask this question of Shaped Tube Electrolytic Machining topic in division Electrochemical Processes of Advanced Machining

Answer»

Right choice is (d) All of the mentioned

The BEST I can explain: Some of the LIMITATIONS of STEM are only used for corrosion resistant materials, HAZARDOUS wastes are generated, special work place ENVIRONMENT are REQUIRED, complex machining and tooling systems are required.

72.

Which of the following values, does the feed rate range between?(a) 0.01 – 0.1 mm/min(b) 0.25 – 0.5 mm/min(c) 0.75 – 3 mm/min(d) 5 – 7.5 mm/minThis question was posed to me by my school principal while I was bunking the class.Origin of the question is Shaped Tube Electrolytic Machining topic in portion Electrochemical Processes of Advanced Machining

Answer»

The correct CHOICE is (c) 0.75 – 3 mm/min

Explanation: FEED RATES USED in STEM, range between 0.75 – 3 mm/min.

73.

What may be the temperatures of acids used, other than sulphuric acid, in STEM?(a) 10 ^oC(b) 21 ^oC(c) 38 ^oC(d) 50 ^oCThe question was asked during an interview.The doubt is from Shaped Tube Electrolytic Machining in section Electrochemical Processes of Advanced Machining

Answer» RIGHT option is (b) 21 ^oC

Easiest EXPLANATION: Temperature of acids used in STEM, other than SULPHURIC ACID, is about 21 ^oC.
74.

What are the voltage values used in the STEM process?(a) 1 – 4 V(b) 8 – 14 V(c) 16 – 24 V(d) 28 – 34 VI got this question by my school teacher while I was bunking the class.I would like to ask this question from Shaped Tube Electrolytic Machining topic in division Electrochemical Processes of Advanced Machining

Answer»

Right choice is (B) 8 – 14 V

To explain: In STEM, voltage values used for the process to CARRY on, RANGE between 8 – 14 V.

75.

What are the values of pressure, used in backward pressure mode of electrolyte flow?(a) 0.01 to 0.12 MPa(b) 0.15 to 0.46 MPa(c) 0.6 to 2 MPa(d) 5 to 12 MPaThis question was posed to me during an interview.My question is taken from Electro Chemical Drilling in portion Electrochemical Processes of Advanced Machining

Answer»

The correct option is (C) 0.6 to 2 MPA

Explanation: To reduce overcut SIZE, reverse flow of electrolyte can be used under backward PRESSURE MODE, whose value ranges between 0.6 to 2 MPa.

76.

The electrolyte is pumped the ________ of tool and exits through _________ of tool.(a) Centre, side(b) Side, centre(c) All of the mentioned(d) None of the mentionedThe question was posed to me in a job interview.I need to ask this question from Electro Chemical Drilling in division Electrochemical Processes of Advanced Machining

Answer»

Right answer is (C) All of the mentioned

Explanation: USUALLY, ELECTROLYTE is pumped from centre and exits from side machining gap and vice-versa can also be DONE in back pressure PROCESS.

77.

Compared to other processes, machining is done at __________ voltages for high rates of material removal.(a) Low(b) Medium(c) High(d) very lowI had been asked this question in a job interview.Enquiry is from ECM-Advantages and Disadvantages in chapter Electrochemical Processes of Advanced Machining

Answer» RIGHT choice is (c) High

For explanation I would SAY: In ECM, machining is DONE at low voltages, when compared to other PROCESSES.
78.

State whether the following statement is true or false regarding the process control of ECM.(a) “In Electrochemical machining, increase in unmanned machining hours reduces the possibility of integration of process with CAD/CAM systems.”(b) True(c) FalseThe question was asked during an interview.The query is from ECM-Process Control topic in chapter Electrochemical Processes of Advanced Machining

Answer»

Correct option is (b) True

The explanation is: An INCREASE in UNMANNED machining HOURS, enhances the PROCESS INTEGRATION with CAD/CAM systems.

79.

Surface roughness depends on current density, which is affected by which of the following?(a) Tool feed rate(b) Gap voltage(c) Work piece material(d) All of the mentionedI had been asked this question by my school teacher while I was bunking the class.Enquiry is from ECM-Process Control topic in section Electrochemical Processes of Advanced Machining

Answer»

Correct option is (d) All of the mentioned

To elaborate: ROUGHNESS depend on current density, which is AFFECTED by tool FEED rate, gap VOLTAGE, work material, PH number, temperature, conductivity and pressure.

80.

What is the approximate value of faraday’s constant?(a) 65,200 C(b) 53,800 C(c) 96,500 C(d) 85,600 CI got this question during an interview for a job.My doubt stems from ECM-Basic Working Principles topic in division Electrochemical Processes of Advanced Machining

Answer»

The correct answer is (c) 96,500 C

To EXPLAIN I WOULD SAY: 1 faraday equals to approximately 96500 C.

81.

What is the role of power supply unit in ECM equipment?(a) Giving feed to tool(b) Electrolyte supply(c) Power supply(d) None of the mentionedThe question was posed to me in an interview for internship.I need to ask this question from ECM topic in section Electrochemical Processes of Advanced Machining

Answer»

Correct CHOICE is (C) Power supply

To explain I would SAY: In ECM, power supply unit is used to supply the MACHINE current at constant dc voltage.

82.

Positively charged particles (cations) move towards which electrode?(a) Anode(b) Cathode(c) Anode & Cathode(d) None of the mentionedThe question was posed to me in an online interview.Question is from ECM-Theory of ECM in chapter Electrochemical Processes of Advanced Machining

Answer» CORRECT CHOICE is (B) Cathode

For explanation: Positively CHARGE particles are directed towards the cathode, which is negatively charged.
83.

Which of the following come under the main components of ECM?(a) Feed control system(b) Work piece holding devices(c) Electrolyte supply system(d) All of the mentionedThe question was asked in semester exam.This is a very interesting question from ECM topic in division Electrochemical Processes of Advanced Machining

Answer»

Right choice is (d) All of the mentioned

Easiest explanation: The main COMPONENTS of Electro chemical machining include feed CONTROL system, electrolyte supply system, power supply UNIT, work PIECE holding devices.

84.

Electro chemical machining process cannot produce which of the following mentioned below?(a) Drilled holes(b) Deburred edges(c) Sharp edges(d) All of the mentionedThe question was asked during an online exam.This intriguing question comes from ECM-Advantages and Disadvantages topic in division Electrochemical Processes of Advanced Machining

Answer»

Correct option is (C) Sharp EDGES

To ELABORATE: Electro chemical machining cannot PRODUCE sharp INTERNAL or external edges.

85.

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) Passive layer on machined parts & cathode(d) None of the mentionedI have been asked this question during an interview for a job.My doubt is from ECM-Process Characteristics in section Electrochemical Processes of Advanced Machining

Answer»

The CORRECT choice is (a) Passive LAYER on machined parts

Explanation: PASSIVATION is DONE on the electrolytes in order to form a passive film on machined parts.

86.

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 mmThis question was addressed to me in quiz.I would like to ask this question from ECM-Process Characteristics topic in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (d) ± 0.25 mm

The EXPLANATION is: The dimensional TOLERANCES OBTAINED for side gaps are ± 0.25 mm.

87.

Which properties of electrolyte does not affect the accuracy of the process?(a) Temperature(b) Concentration(c) Non-reactive(d) PressureThe question was posed to me during a job interview.Question is from ECM-Process Characteristics topic in section Electrochemical Processes of Advanced Machining

Answer»

The CORRECT answer is (c) Non-reactive

To explain: Electrolyte MUST be reactive in order to carry on the reactions that OCCUR at the ELECTRODES.

88.

Local metal removal rates are high at which gap locations mentioned below?(a) Small gap(b) Medium gap(c) Large gap(d) None of the mentionedThe question was asked during an internship interview.Question is from ECM in section Electrochemical Processes of Advanced Machining

Answer»

Right choice is (a) SMALL gap

Easy explanation: Local METAL removal RATES are high at small gap locations in ECM.

89.

What must be the value of the pressure of electrolytic solution used in ECM?(a) 1 to 10 kPa(b) 10 to 80 kPa(c) 100 to 200 kPa(d) 300 to 400 kPaThe question was asked in an interview for job.My question is based upon ECM topic in portion Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (c) 100 to 200 kPa

The EXPLANATION: Value of PRESSURE of electrolytic solution must RANGE between 100 to 200 kPa.

90.

For large size machining, which type of facilities are used in ECM?(a) Semi-automated facilities(b) Automated facilities(c) Automated & Semi-automated facilities(d) None of the mentionedThe question was asked in an interview.This is a very interesting question from ECM in section Electrochemical Processes of Advanced Machining

Answer»

The correct CHOICE is (c) Automated & Semi-automated FACILITIES

Explanation: Automated and semi-automated facilities are used for LARGE size MACHINING.

91.

Of the following, which type of electrodes is used as tool in ECDR?(a) Tubular electrodes(b) Flat electrodes(c) Cylindrical electrodes(d) All of the mentionedThis question was addressed to me by my college professor while I was bunking the class.The query is from Electro Chemical Drilling in portion Electrochemical Processes of Advanced Machining

Answer»

The CORRECT option is (a) Tubular ELECTRODES

The BEST I can explain: In ECDR, tubular electrodes are USED as cathodic tools for making holes in the materials.

92.

How are material removal rates of ECM, when compared to that of conventional methods?(a) Slower(b) Faster(c) Same(d) None of the mentionedI had been asked this question by my college director while I was bunking the class.My question is from ECM-Advantages and Disadvantages topic in portion Electrochemical Processes of Advanced Machining

Answer»

Right choice is (a) Slower

The explanation is: In ECM, rates of MATERIAL removal are SLOW compared to CONVENTIONAL methods.

93.

Which of the following material cannot be machined using ECM?(a) High strength alloys(b) Hardened steels(c) Nonconductive materials(d) All of the mentionedI have been asked this question in my homework.My query is from ECM-Applications and Micro-ECM topic in portion Electrochemical Processes of Advanced Machining

Answer»

Right OPTION is (c) Nonconductive materials

To explain: ECM can be used for machining high STRENGTH alloys and hardened steels which LED to many cost-saving applications.

94.

Between which values does the side gap’s surface roughness vary?(a) >1 µm(b) >3 µm(c) >5 µm(d) >7 µmI got this question by my college professor while I was bunking the class.Enquiry is from ECM-Process Characteristics topic in chapter Electrochemical Processes of Advanced Machining

Answer»

Correct CHOICE is (C) >5 µm

To explain: SURFACE roughness value is 5 µm or more for side gap AREAS.

95.

Which type of electrical conductivity is necessary for electrolytic solution?(a) Low(b) Medium(c) High(d) None of the mentionedThis question was posed to me in final exam.My doubt is from ECM topic in division Electrochemical Processes of Advanced Machining

Answer»

Correct CHOICE is (C) High

Explanation: High electrical conductivity is needed for ELECTROLYTIC SOLUTION in ECM.

96.

State whether the following statement is true or false regarding the theory of ECM.(a) lead to occurrence of several reactions.”(b) True(c) FalseThis question was posed to me in an internship interview.The query is from ECM-Theory of ECM in section Electrochemical Processes of Advanced Machining

Answer»

The correct option is (a) lead to occurrence of several REACTIONS.”

For EXPLANATION: When P.D (POTENTIAL DIFFERENCE) is applied, different reactions OCCUR at anode and cathode.

97.

Which of the following material removal mechanisms is implemented by ECM?(a) Mechanical abrasion(b) Electrochemical dissolution(c) Chemical corrosion(d) Mechanical erosionThis question was posed to me in an online interview.The query is from Electro Chemical Machining-Introduction and Principle of electrolysis in division Electrochemical Processes of Advanced Machining

Answer» RIGHT option is (b) ELECTROCHEMICAL dissolution

The best explanation: In ECM, MATERIAL is REMOVED by electrochemical dissolution.
98.

Very small dimensions, up to which value can be controlled using ECM?(a) 0.01 mm(b) 0.05 mm(c) 0.07 mm(d) 0.12 mmThe question was posed to me in my homework.My question comes from ECM-Advantages and Disadvantages topic in section Electrochemical Processes of Advanced Machining

Answer»

Right OPTION is (b) 0.05 MM

Easiest EXPLANATION: Due to less electrode gap very small DIMENSIONS up to 0.05 mm can be controlled.

99.

In micro ECM, which of the following is used as micro tool?(a) Electrolyte jet(b) Electrodes(c) Power supply(d) All of the mentionedI have been asked this question during an interview for a job.My question is based upon ECM-Applications and Micro-ECM in section Electrochemical Processes of Advanced Machining

Answer»

Right ANSWER is (a) ELECTROLYTE JET

The explanation is: Electrolyte jet in micro ECM acts as the micro tool for machining.

100.

Which type of damage is caused by deterioration which is caused by spark?(a) Reparable(b) Irreparable(c) All of the mentioned(d) None of the mentionedThis question was posed to me in examination.I need to ask this question from ECM-Process Control in section Electrochemical Processes of Advanced Machining

Answer»

The correct choice is (B) Irreparable

The best I can EXPLAIN: Deterioration by sparking MAY cause irreparable damage to the work PIECES.