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101.

What happens to the product cycle time, if the machining performance is improved?(a) Increases(b) Decreases(c) Remains same(d) None of the mentionedThe question was posed to me in my homework.My question comes from ECM-Process Control in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct CHOICE is (b) Decreases

To EXPLAIN I would say: As the machining performance is improved, the TIME TAKE for a product to complete its production CYCLE, decreases.

102.

What are the typical dimensional tolerances for frontal gaps in ECM?(a) ± 0.01 mm(b) ± 0.025 mm(c) ± 0.13 mm(d) ± 0.25 mmThe question was posed to me in a national level competition.This interesting question is from ECM-Process Characteristics in division Electrochemical Processes of Advanced Machining

Answer»

The correct option is (C) ± 0.13 MM

The BEST I can explain: The dimensional tolerances obtained for FRONTAL gaps are ± 0.130 mm.

103.

How much should be the electrolytic solution?(a) Highly expensive(b) Inexpensive(c) All of the mentioned(d) None of the mentionedThe question was asked in an online quiz.This interesting question is from ECM in chapter Electrochemical Processes of Advanced Machining

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Correct option is (B) INEXPENSIVE

For explanation: Electrolyte MUST be inexpensive and available at EASE.

104.

Accuracy of machining is affected by, which of the following factors?(a) Material(b) Gap voltage(c) Feed rate(d) All of the mentionedThis question was addressed to me in a job interview.Question is taken from ECM-Process Characteristics in portion Electrochemical Processes of Advanced Machining

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Right answer is (d) All of the mentioned

To elaborate: ACCURACY of the process is AFFECTED by material EQUIVALENT, gap voltage, feed RATE, etc.

105.

For alloys, which type of electrolyte is used in ECM?(a) Single component(b) Double component(c) Multi component(d) Triple componentThe question was posed to me during an internship interview.Question is taken from ECM-Process Characteristics topic in section Electrochemical Processes of Advanced Machining

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Correct choice is (C) MULTI component

To EXPLAIN: DEPENDING up on the elements in an alloy multi component electrolytes are used.

106.

What is the value of the current density used in Electrochemical machining?(a) 0.01 – 0.4 A/mm^2(b) 0.5 – 5 A/mm^2(c) 6 – 15 A/mm^2(d) 20 – 50 A/mm^2The question was posed to me during an interview for a job.This interesting question is from ECM-Theory of ECM topic in division Electrochemical Processes of Advanced Machining

Answer»

Right OPTION is (B) 0.5 – 5 A/mm^2

To explain: HIGH current densities, which range between 0.5 – 5 A/mm^2 are used in ECM.

107.

Which of the following produces small indents and cavities using micro ECM?(a) Moving the work piece(b) Switching the pulse current(c) Moving the work piece & Switching the pulse current(d) None of the mentionedThis question was addressed to me at a job interview.My query is from ECM-Applications and Micro-ECM in portion Electrochemical Processes of Advanced Machining

Answer» CORRECT answer is (c) Moving the WORK piece & Switching the pulse current

For explanation: Indentation and cavitation can be DONE USING MICRO ECM by moving the work piece or switching the pulse current.
108.

The cost of additional control hardware remain a _________ fraction of total machining cost.(a) Small(b) Large(c) Equal(d) None of the mentionedThe question was asked during an internship interview.Question is taken from ECM-Process Control in division Electrochemical Processes of Advanced Machining

Answer»

Correct choice is (a) Small

To ELABORATE: Cost of ADDITIONAL control hardware is very less, which CONSTITUTES to a small fraction in total machining cost.

109.

In Electrochemical machining, larger grain size causes which type of finish?(a) Smoother(b) Rougher(c) Finer(d) All of the mentionedI got this question in examination.Enquiry is from ECM-Process Characteristics in section Electrochemical Processes of Advanced Machining

Answer»

The CORRECT option is (b) Rougher

The EXPLANATION: In ECM, LARGER grains cause rougher finish than finer grains.

110.

Which of the following factors are used to determine the tool geometry?(a) Required shape(b) Electrical conductivity(c) Tool feed rate(d) All of the mentionedI have been asked this question by my college professor while I was bunking the class.Asked question is from ECM topic in portion Electrochemical Processes of Advanced Machining

Answer»

Right answer is (d) All of the mentioned

To explain: For determining a TOOL geometry we must specify some factors such as the required SHAPE of the surface, tool feed rate, gap voltage, electrochemical machinability of the WORK material, ELECTROLYTE CONDUCTIVITY, and both electrodes’ polarization voltages.

111.

Which type of adjustment is to be done for gap voltages?(a) Continuous adjustment(b) Discontinuous adjustment(c) Periodic adjustment(d) All of the mentionedThe question was posed to me in an internship interview.The question is from ECM topic in chapter Electrochemical Processes of Advanced Machining

Answer» RIGHT choice is (a) Continuous ADJUSTMENT

Explanation: In ECM, USUALLY continuous adjustment of gap voltage is REQUIRED.
112.

Electrolyte supply system should concentrate on which of the following factors?(a) Pressure(b) Supply rate(c) Temperature(d) All of the mentionedThe question was asked in unit test.Origin of the question is ECM topic in section Electrochemical Processes of Advanced Machining

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

Easiest explanation: Electrolyte supply system should supply electrolyte at a given RATE, TEMPERATURE and PRESSURE.
113.

In ECM equipment, what is the role of electrolyte supply system?(a) Giving feed to tool(b) Electrolyte supply(c) Power supply(d) None of the mentionedThis question was addressed to me by my college director while I was bunking the class.This interesting question is from ECM in chapter Electrochemical Processes of Advanced Machining

Answer» RIGHT CHOICE is (b) Electrolyte supply

Explanation: As the name itself INDICATES, electrolyte supply system is used to supply the electrolyte required for ANODIC dissolution.
114.

Of the following, electrolyte removes which of the dissolution products?(a) Metal hydroxides(b) Heat(c) Gas bubbles(d) All of the mentionedThe question was asked in an interview.Question is from ECM-Theory of ECM topic in section Electrochemical Processes of Advanced Machining

Answer»

Correct ANSWER is (d) All of the mentioned

For explanation I WOULD say: ELECTROLYTE removes the dissolution products such as metal HYDROXIDES, heat and gas bubbles formed in the inter electrode gap.

115.

What are the values of diameters produced using Electrochemical drilling process?(a) 0.01 to 0.2 mm(b) 1 to 20 mm(c) 30 to 50 mm(d) 60 to 100 mmThe question was asked during an internship interview.This interesting question is from Electro Chemical Drilling topic in section Electrochemical Processes of Advanced Machining

Answer» RIGHT choice is (B) 1 to 20 mm

For explanation I WOULD say: Value of diameter produced using Electrochemical DRILLING, RANGES between 1 to 20 mm.
116.

What are the requirements of labour for machining purpose in Electrochemical machining?(a) Low(b) Medium(c) High(d) Very highThis question was posed to me at a job interview.Asked question is from ECM-Advantages and Disadvantages in division Electrochemical Processes of Advanced Machining

Answer»

Correct option is (a) LOW

The best explanation: In electrochemical machining, labour REQUIREMENTS are low COMPARED to conventional or TRADITIONAL machining PRACTICES.

117.

Complicated profiles can be machined in how many operations in Electrochemical machining?(a) Single(b) Double(c) Triple(d) MultipleI got this question by my college professor while I was bunking the class.I want to ask this question from ECM-Advantages and Disadvantages topic in division Electrochemical Processes of Advanced Machining

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Right choice is (a) SINGLE

The explanation is: ONE of the main ADVANTAGE of ECM is, complicated PROFILES can be MACHINED in a single operation itself.

118.

With an increase in unmanned machining hours, what happens to the efficiency of ECM?(a) Increases(b) Reduces(c) Decreases(d) Increase and then decreaseI had been asked this question during an interview.I need to ask this question from ECM-Process Control topic in division Electrochemical Processes of Advanced Machining

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The correct answer is (a) Increases

The best I can explain: INCREASE in UNMANNED machining HOURS lead to a RAISE in efficiency of ECM.

119.

What happens when the current density is low in ECM?(a) Pitting occurs(b) Etching occurs(c) Pitting & Etching occurs(d) None of the mentionedThis question was addressed to me during an interview.Origin of the question is ECM-Process Characteristics topic in chapter Electrochemical Processes of Advanced Machining

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The correct OPTION is (c) PITTING & Etching occurs

For explanation: When CURRENT density is lower than optimum, then etching and pitting occurs which are undesired.

120.

For a better surface finish, which type of current distribution is required?(a) Even(b) Uneven(c) Even & Uneven(d) None of the mentionedThis question was posed to me at a job interview.I need to ask this question from ECM-Process Characteristics topic in division Electrochemical Processes of Advanced Machining

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Correct answer is (a) EVEN

Explanation: More even distribution of the CURRENT density LEADS to a better surface FINISH.

121.

State whether the following statement is true or false about electrolyte in ECM.(a) “Machinability in ECM is enhanced, when electrolyte is heated.”(b) True(c) FalseThe question was posed to me by my college director while I was bunking the class.Query is from ECM-Process Characteristics topic in section Electrochemical Processes of Advanced Machining

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Right choice is (a) “Machinability in ECM is enhanced, when electrolyte is HEATED.”

For explanation: Machinability is increased, when electrolyte is heated, as heating increases the SPECIFIC CONDUCTIVITY of the electrolyte.

122.

What must be the working voltage in Electrochemical machining?(a) 10 V(b) 20 V(c) 30 V(d) 40 VThe question was asked in examination.Question is from ECM-Process Characteristics topic in section Electrochemical Processes of Advanced Machining

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Right OPTION is (B) 20 V

The EXPLANATION: The electrolytes in ECM employ a working voltage up to 20 V.

123.

When the electrolyte flow is low, what happens to the current efficiency?(a) Increases(b) Decreases(c) Remains same(d) Increase and then decreaseThe question was posed to me by my college professor while I was bunking the class.I need to ask this question from ECM-Process Characteristics in division Electrochemical Processes of Advanced Machining

Answer» CORRECT choice is (b) Decreases

For explanation I would say: In ECM, if the ELECTROLYTE flow is low, current efficiency is reduced DUE to the accumulation of machining products within the gap.
124.

State whether the following statement is true or false regarding the working principles.(a) “In ECM, grain boundary attacks remove the grains through electrolytic forces.”(b) True(c) FalseThis question was addressed to me in quiz.The doubt is from ECM-Basic Working Principles in section Electrochemical Processes of Advanced Machining

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The correct answer is (a) “In ECM, grain BOUNDARY ATTACKS remove the GRAINS through electrolytic forces.”

The explanation: In ECM, grain boundary attacks are the cause for removal of grains by electrolytic forces.

125.

At constant gap thickness material removal becomes equal to feed rate. What is this gap called?(a) Equal gap(b) Equilibrium gap(c) Unique gap(d) Narrow gapI had been asked this question in a national level competition.I need to ask this question from ECM-Basic Working Principles in division Electrochemical Processes of Advanced Machining

Answer» CORRECT option is (b) Equilibrium gap

Easy explanation: When rate of MATERIAL REMOVAL PER unit area is same as feed rate, then CORRESPONDING thickness is called as equilibrium thickness indicated by ‘ye’.
126.

State whether the following statement is true or false regarding the electrolytes in ECM.(a) “In Electrochemical machining, electrolytes should deposit on cathode electrodes.”(b) True(c) FalseI got this question by my college professor while I was bunking the class.The doubt is from ECM in division Electrochemical Processes of Advanced Machining

Answer»

The correct option is (b) True

Easy EXPLANATION: In ECM, electrolytes should not deposit on cathode, so that shape of electrode REMAINS UNCHANGED.

127.

Electrolytic solution should ensure which type of anodic dissolution?(a) Uniform(b) Non-uniform(c) Low speed(d) None of the mentionedI had been asked this question during an internship interview.My doubt is from ECM topic in chapter Electrochemical Processes of Advanced Machining

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Right choice is (a) Uniform

To explain I would say: Uniform and high SPEED anodic dissolution MUST be ENSURED by the electrolyte.

128.

The system which consists of electrolytic solution and electrodes can be referred to as ____________(a) Electrolytic cell(b) Electrode system(c) Electrolytic system(d) Electrode cellI got this question in an interview for job.This intriguing question originated from Electro Chemical Machining-Introduction and Principle of electrolysis in chapter Electrochemical Processes of Advanced Machining

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Right option is (a) Electrolytic cell

Easy explanation: The SYSTEM of ELECTRODES and electrolytic SOLUTION is REFERRED as electrolytic cell.

129.

ECM is usually characterized as low accuracy machining, for which of the following reason?(a) Narrow gap width(b) Wider gap width(c) High current densities(d) All of the mentionedI had been asked this question at a job interview.My enquiry is from ECM-Applications and Micro-ECM topic in portion Electrochemical Processes of Advanced Machining

Answer»

Right option is (B) Wider gap width

The explanation: ECM is usually CHARACTERIZED as low ACCURACY machining because of its wider machining gap.

130.

What is the value of moderate level of pH of electrolyte used?(a) 1 – 2(b) 2 – 4(c) 4 – 10(d) All of the mentionedThe question was asked by my school teacher while I was bunking the class.This intriguing question originated from ECM-Process Characteristics topic in chapter Electrochemical Processes of Advanced Machining

Answer» CORRECT choice is (c) 4 – 10

The best I can explain: MODERATE level of pH of electrolyte USED in ECM range between 4 – 10.
131.

Better surface finish and higher accuracy depend on which of the factors below?(a) Chemical composition of the electrolyte(b) Current density(c) All of the mentioned(d) None of the mentionedThis question was posed to me in an online quiz.I want to ask this question from ECM-Process Characteristics in division Electrochemical Processes of Advanced Machining

Answer»

The correct option is (c) All of the mentioned

To EXPLAIN I would SAY: Proper chemical composition of ELECTROLYTE and proper current density are RESPONSIBLE for better surface finish and accuracy.

132.

If the gap thickness is greater than equilibrium thickness what will be MRR?(a) MRR is less than feed rate(b) MRR is greater than feed rate(c) MRR is equal to feed rate(d) None of the mentionedThe question was asked by my college director while I was bunking the class.This interesting question is from ECM-Basic Working Principles in section Electrochemical Processes of Advanced Machining

Answer» RIGHT option is (a) MRR is less than FEED rate

The explanation is: When GAP thickness is greater than equilibrium thickness, MRR will be less than feed rate.
133.

What are the main functions of electrolyte in Electrochemical machining?(a) Conduct machining current(b) Removal of debris(c) Maintaining constant temperature(d) All of the mentionedThe question was asked in an interview for internship.Question is taken from ECM in section Electrochemical Processes of Advanced Machining

Answer»

Correct option is (d) All of the mentioned

Explanation: Main FUNCTIONS of ELECTROLYTE are conducting machine current, removing the DEBRIS, carrying away the heat, maintaining CONSTANT TEMPERATURE.

134.

When local metal removal rates are high, how will be the current density and current efficiency?(a) High(b) Medium(c) Low(d) Very lowI had been asked this question in quiz.Query is from ECM topic in section Electrochemical Processes of Advanced Machining

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Correct choice is (a) High

Best EXPLANATION: When the LOCAL metal REMOVAL RATES are high then current density and efficiency are also high.

135.

Between which of the following values, does the current range?(a) 0.002 to 0.01 A(b) 0.01 to 10 A(c) 50 to 10000 A(d) 105 to 106 AI got this question in an online interview.Question is taken from ECM topic in portion Electrochemical Processes of Advanced Machining

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Correct OPTION is (C) 50 to 10000 A

Explanation: In ELECTROCHEMICAL machining, current value RANGES between 50 to 10000 A.

136.

The chemical reactions occurring at electrodes are called with, which of the following names?(a) Anodic reactions(b) Cathode reactions(c) All of the mentioned(d) None of the mentionedI had been asked this question in examination.I want to ask this question from Electro Chemical Machining-Introduction and Principle of electrolysis topic in chapter Electrochemical Processes of Advanced Machining

Answer» CORRECT answer is (C) All of the mentioned

The explanation is: Chemical REACTIONS occurring at ELECTRODES are called as ANODIC or cathodic reactions.
137.

What fraction of tool will always be in contact with the work piece?(a) Half(b) Full(c) No contact(d) QuarterThis question was posed to me in my homework.I'm obligated to ask this question of ECM-Advantages and Disadvantages in section Electrochemical Processes of Advanced Machining

Answer»

Correct option is (c) No contact

The EXPLANATION: Tool does not have any contact with the WORK PIECE in Electro CHEMICAL MACHINING.

138.

What is the value of the overcut that is obtained using ECM?(a) 0.3 mm(b) 0.5 mm(c) 0.7 mm(d) 0.9 mmThe question was asked in a job interview.My question is from ECM-Process Characteristics in section Electrochemical Processes of Advanced Machining

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Right answer is (b) 0.5 mm

To explain: An OVERCUT of 0.5 mm is OBTAINED when machined using ECM.

139.

Fine dimensional control can be obtained if throwing power of electrolyte is ___________(a) Low(b) Medium(c) High(d) Very highI have been asked this question during an interview.My enquiry is from ECM-Process Characteristics in portion Electrochemical Processes of Advanced Machining

Answer» CORRECT choice is (a) Low

The BEST I can explain: THROWING power of electrolyte must be less in ORDER to obtain a FINE dimensional control.
140.

Which type of gap width is necessary for a higher degree of accuracy?(a) Very small(b) Small(c) Medium(d) HighThis question was addressed to me during an online interview.The doubt is from ECM-Process Characteristics topic in division Electrochemical Processes of Advanced Machining

Answer» RIGHT choice is (b) Small

The best EXPLANATION: A small GAP width represents a high LEVEL of accuracy. Very small gap width results in sparks and short circuits.
141.

What must be the value of electrolytic temperature in ECM?(a) 2 to 14^oC(b) 22 to 45^oC(c) 46 to 57^oC(d) 62 to 76^oCI had been asked this question in an interview for internship.My doubt stems from ECM in portion Electrochemical Processes of Advanced Machining

Answer»

The correct OPTION is (B) 22 to 45^oC

The best explanation: Temperature of ELECTROLYTE should RANGE between 22 to 45^oC.

142.

In practice, what must be the temperature of electrolyte used in ECM?(a) 10 – 20^oC(b) 20 – 40^oC(c) 60 – 80^oC(d) 80 – 100^oCThe question was asked in final exam.This interesting question is from ECM-Process Characteristics in portion Electrochemical Processes of Advanced Machining

Answer»

Correct ANSWER is (c) 60 – 80^oC

The explanation is: Temperature of electrolyte USED in ECM must not EXCEED 60 – 70^oC.

143.

Which are the most common electrolytes used in Electrochemical machining?(a) Sodium chloride(b) Sodium nitride(c) Sodium hydroxide(d) All of the mentionedI have been asked this question by my school teacher while I was bunking the class.Query is from ECM topic in portion Electrochemical Processes of Advanced Machining

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

Explanation: Electrolytes such as SODIUM chloride, sodium NITRIDE, sodium HYDROXIDE are some of the electrolytes used in ECM.
144.

Which of the following reaction takes place at anode?(a) Generation of hydrogen(b) Dissolution of iron(c) Generation of hydroxyl ions(d) None of the mentionedI had been asked this question by my school principal while I was bunking the class.My question is from ECM-Theory of ECM in division Electrochemical Processes of Advanced Machining

Answer» RIGHT choice is (B) DISSOLUTION of iron

The explanation is: At anode, dissolution of FE takes place in the process of ECM.
145.

In advanced machining processes, what is the full form of ECM?(a) Electrochemical manufacturing(b) Electrochemical milling(c) Electrochemical machining(d) Electrochemical maskingThis question was addressed to me in an interview for job.My question is based upon Electro Chemical Machining-Introduction and Principle of electrolysis topic in section Electrochemical Processes of Advanced Machining

Answer»

Right option is (b) Electrochemical milling

Best explanation: In ADVANCED machining PROCESSES, FULL form of ECM is Electrochemical machining.

146.

Which of the following materials can be machined using ECM?(a) Hard nonconductive materials(b) Hard conductive materials(c) All nonconductive materials(d) None of the mentionedI have been asked this question during an interview for a job.I would like to ask this question from ECM-Advantages and Disadvantages in section Electrochemical Processes of Advanced Machining

Answer»

Correct option is (b) Hard conductive materials

To EXPLAIN I would say: Hard conductive materials can be machined and NONCONDUCTIVE materials cannot be machined using ECM.

147.

How much amount of thermal damage occurs to the work piece?(a) Small(b) Large(c) No thermal damage(d) Negligible amountI have been asked this question in unit test.This intriguing question comes from ECM-Advantages and Disadvantages topic in division Electrochemical Processes of Advanced Machining

Answer»

The CORRECT answer is (c) No THERMAL damage

To explain I would say: As the temperatures are very low, no thermal damage OCCURS to the work piece MATERIAL.

148.

If there is a change in the selected machining conditions, it will have impact on which of the following?(a) Process accuracy(b) Surface finish(c) Process accuracy & Surface finish(d) None of the mentionedI had been asked this question in semester exam.This intriguing question comes from ECM-Process Control topic in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct choice is (c) PROCESS accuracy & SURFACE finish

For explanation: SELECTED machining conditions should remain UNCHANGED, because, it will have a direct IMPACT on accuracy and surface finish.

149.

When machining Ti, in Nacl electrolyte, what values of current efficiencies are obtained?(a) 10 – 20 %(b) 20 – 30 %(c) 30 – 50 %(d) 50 – 80 %I had been asked this question in an internship interview.Question is from ECM-Process Characteristics in division Electrochemical Processes of Advanced Machining

Answer»

Right answer is (a) 1020 %

For explanation I would say: While machining Ti USING NaCl ELECTROLYTE, current efficiencies of 10 – 20 percent are obtained.

150.

What is the value of voltage that the power supply unit supplies for ECM?(a) 0.01 to 1 V(b) 2 to 30 V(c) 50 to 80 V(d) 100 to 160 VI got this question in an interview.My enquiry is from ECM in division Electrochemical Processes of Advanced Machining

Answer»

The correct answer is (b) 2 to 30 V

Explanation: Voltage supply REQUIRED for ECM RANGES between 2 to 30 V.