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151.

Which of the following reactions takes place at the electrodes?(a) Generation of hydrogen(b) Dissolution of iron(c) Dissolution of NaCl(d) All of the mentionedThis question was posed to me in class test.I'm obligated to ask this question of ECM-Theory of ECM in division Electrochemical Processes of Advanced Machining

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

To elaborate: All the REACTIONS mentioned above, take place at different ELECTRODES in ECM.
152.

Which of the following are some of the bad impacts on environment while using ECM?(a) Electrolyte splashing(b) Toxic gases release(c) Precipitation of solid matters(d) All of the mentionedI have been asked this question by my school teacher while I was bunking the class.I would like to ask this question from ECM-Environmental Impact topic in chapter Electrochemical Processes of Advanced Machining

Answer»

The CORRECT CHOICE is (d) All of the mentioned

For explanation I would SAY: Electrolyte splashing, precipitation of solid MATTER, and toxic gas release is very HARMFUL to the environment.

153.

Slurries mixing with toxic compounds produce, which of the following?(a) Solid precipitates(b) Liquid solutions(c) All of the mentioned(d) None of the mentionedI got this question during an internship interview.Question is taken from ECM-Environmental Impact topic in section Electrochemical Processes of Advanced Machining

Answer» RIGHT answer is (a) Solid PRECIPITATES

Easiest explanation: SLURRIES which MIX with TOXIC compounds such as chromate and ammonia precipitates solid matter in the electrolyte solution.
154.

State whether the following statement is true or false regarding the limitations of ECM.(a) “In electrochemical machining, duplicating the tool is easier.”(b) True(c) FalseThe question was posed to me in unit test.My question is taken from ECM-Advantages and Disadvantages in portion Electrochemical Processes of Advanced Machining

Answer»

Correct answer is (b) True

The explanation: Duplication of TOOL is DIFFICULT in ECM, since it has side machining EFFECTS.

155.

How much amount of wear is present in the tool used in Electrochemical machining?(a) No wear(b) Low(c) Medium(d) HighI have been asked this question in an international level competition.My question is taken from ECM-Advantages and Disadvantages in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct option is (a) No wear

To explain I would SAY: The tool wear is ABSENT in the tool used in ECM, since tool has no CONTACT with the work piece.

156.

Which of the following use ECM for different applications?(a) Gas turbines(b) Jet engines(c) Bio medical implants(d) All of the mentionedThe question was asked in an international level competition.My enquiry is from ECM-Applications and Micro-ECM topic in portion Electrochemical Processes of Advanced Machining

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

The explanation: ECM has its APPLICATIONS in industries such as gas TURBINES, JET ENGINES, automobiles, medical etc.
157.

What are the typical dimensional tolerances obtained in ECM when there is proper control of machining?(a) ± 0.01 mm(b) ± 0.025 mm(c) ± 0.13 mm(d) ± 0.25 mmThe question was asked during an interview for a job.My question is from ECM-Process Characteristics in portion Electrochemical Processes of Advanced Machining

Answer»

Correct OPTION is (b) ± 0.025 mm

Explanation: The dimensional TOLERANCES obtained by PROPER MACHINING are ± 0.025 mm.

158.

Non stationary behaviour of ECM is due to, which of the factors below?(a) Gas generation(b) Heating(c) Passivation(d) All of the mentionedI have been asked this question at a job interview.This intriguing question originated from ECM-Process Control topic in section Electrochemical Processes of Advanced Machining

Answer»

Right ANSWER is (d) All of the mentioned

For EXPLANATION: Non stationary behaviour of ECM is due to the inter electrode gap CONDITIONS such as gas generation, PASSIVATION, heating and other electrode reactions.

159.

For high process accuracy, which of the following factors are needed?(a) High feed rate(b) High conductivity(c) High feed rate & High conductivity(d) None of the mentionedI had been asked this question in an online interview.This key question is from ECM-Process Characteristics in section Electrochemical Processes of Advanced Machining

Answer»

Correct option is (c) High feed rate & High conductivity

Explanation: For a higher degree of ACCURACY, there MUST be high feed rates and highly CONDUCTIVE electrolytes.

160.

Nickel can be machined with 100% current efficiency, when current density value is ______________(a) 10 A/cm^2(b) 25 A/cm^2(c) 45 A/cm^2(d) 80 A/cm^2This question was posed to me by my school principal while I was bunking the class.This key question is from ECM-Process Characteristics topic in portion Electrochemical Processes of Advanced Machining

Answer» RIGHT ANSWER is (b) 25 A/cm^2

The explanation: NICKEL is a metal SUGGESTED by Khayry, which can be machined at 100% current EFFICIENCY, if current density is 25 A/cm^2.
161.

Selection of electrolyte does not depend on which of the following factors?(a) Work piece material(b) Dimensional tolerance(c) Heat affected zones(d) Machining productivityThis question was addressed to me in an interview for internship.This question is from ECM topic in section Electrochemical Processes of Advanced Machining

Answer»

The correct answer is (C) Heat AFFECTED zones

Best explanation: SELECTION of electrolyte depend up on work piece MATERIAL, dimensional tolerance, machining productivity and surface finish required.

162.

What must be the value of velocity of the electrolytic solution?(a) 10 to 15 m/s(b) 25 to 50 m/s(c) 60 to 100 m/s(d) 120 to 200 m/sThe question was posed to me in semester exam.My query is from ECM topic in division Electrochemical Processes of Advanced Machining

Answer»

Correct choice is (B) 25 to 50 m/s

Best explanation: TYPICAL velocity of the electrolytic SOLUTION must range between 25 to 50 m/sec.

163.

For high strength or rigidity, which type of coatings are recommended for metals?(a) Other metal coatings(b) Non-metallic coatings(c) All of the mentioned(d) None of the mentionedThe question was asked in final exam.Asked question is from ECM in chapter Electrochemical Processes of Advanced Machining

Answer»

The CORRECT choice is (b) Non-metallic COATINGS

The explanation: For high STRENGTH and RIGIDITY, non-metallic coatings are recommended for metals.

164.

Electrolysis occur when which of the following takes place between electrodes?(a) Electric current flow(b) Electron flow(c) All of the mentioned(d) None of the mentionedI got this question in semester exam.My question is based upon Electro Chemical Machining-Introduction and Principle of electrolysis in chapter Electrochemical Processes of Advanced Machining

Answer»

Right ANSWER is (C) All of the mentioned

Explanation: When there is an electron FLOW there is current flow in the opposite direction. For ELECTROLYSIS to take place there should be flow of current between electrodes.

165.

Which of the following are the simplest methods for applying the insulation on tools?(a) Spraying(b) Dipping(c) All of the mentioned(d) None of the mentionedThis question was posed to me in a national level competition.This question is from ECM in portion Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (c) All of the mentioned

Best EXPLANATION: In ECM, dipping or spraying are the simplest METHODS for INSULATING the tools.

166.

Pumping of electrolyte through the narrow gaps causes, which type of forces on tool and work piece?(a) Large(b) Small(c) Negligible(d) No forceThe question was asked in an interview.My question is from ECM-Advantages and Disadvantages topic in portion Electrochemical Processes of Advanced Machining

Answer» CORRECT option is (a) Large

Best explanation: ELECTROLYTE pumping through the NARROW gaps gives rise to a large amount of FORCES on tool and work PIECES.
167.

Between which values does the frontal gap’s surface roughness vary?(a) 0.02 to 0.13 µm(b) 0.30 to 1.90 µm(c) 1.93 to 2.64 µm(d) 2.73 to 4.26 µmThis question was addressed to me in an interview for job.I want to ask this question from ECM-Process Characteristics topic in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (b) 0.30 to 1.90 µm

The explanation: Surface roughness VARIES between 0.30 to 1.9 µm for FRONTAL gap AREA.

168.

Tool insulation that __________ the side machining action is needed in the process of ECM.(a) Limits(b) Enhances(c) Maintains(d) None of the mentionedThis question was addressed to me by my school principal while I was bunking the class.This question is from ECM-Process Characteristics topic in portion Electrochemical Processes of Advanced Machining

Answer» CORRECT ANSWER is (a) Limits

For explanation: Tool INSULATION is needed, which limits the machining of other sides of work PIECE.
169.

Surface roughness depend on which of the following quantities?(a) Crystallographic irregularities(b) Alloy composition(c) Distribution of current density(d) All of the mentionedI got this question by my college director while I was bunking the class.Origin of the question is ECM-Process Characteristics in portion Electrochemical Processes of Advanced Machining

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

Easiest explanation: Surface roughness of machined surface in ECM depend on crystallographic irregularities, alloy composition, CURRENT DENSITY distribution, dislocations and GRAIN boundaries.
170.

In ECM, gap increase proportional to which relation of time below?(a) Square of time(b) Square root of time(c) Cube of time(d) Cube root of timeI have been asked this question by my school teacher while I was bunking the class.Asked question is from ECM-Basic Working Principles topic in portion Electrochemical Processes of Advanced Machining

Answer»

Correct ANSWER is (b) Square root of time

To EXPLAIN: In Electrochemical machining, GAP INCREASES proportional to the square root of time.

171.

State whether the following statement is true or false regarding the electrolytic solution.(a) “In ECM, formation of passive film is recommended.”(b) True(c) FalseThe question was posed to me in unit test.Query is from ECM topic in chapter Electrochemical Processes of Advanced Machining

Answer» CORRECT choice is (b) True

Explanation: ELECTROLYTIC solution should AVOID formation of PASSIVE layers on ANODE.
172.

Which of the following reactions take place at cathode?(a) Generation of hydrogen(b) Dissolution of iron(c) Dissolution of NaCl(d) All of the mentionedI got this question in quiz.The doubt is from ECM-Theory of ECM topic in section Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (a) Generation of HYDROGEN

The best I can EXPLAIN: At cathode, generation of hydrogen takes place in the PROCESS of ECM.

173.

During deburring and die sinking which of the following electrolyte gives high surface quality and accuracy?(a) NaNO3(b) HNO3(c) NaCl(d) All of the mentionedThe question was posed to me in an interview.Origin of the question is ECM-Environmental Impact in section Electrochemical Processes of Advanced Machining

Answer»

The CORRECT choice is (a) NaNO3

To ELABORATE: By using NaNO3, deburring and die sinking can be done with more ACCURACY and high qualities are OBTAINED.

174.

What is the full form of ECDR in advanced machining processes?(a) Electrochemical Dissolution(b) Electrochemical Drilling(c) Electrochemical Degradation(d) Electrochemical DevastationThe question was asked by my college professor while I was bunking the class.Enquiry is from Electro Chemical Drilling topic in division Electrochemical Processes of Advanced Machining

Answer» RIGHT option is (B) Electrochemical Drilling

Easy explanation: In advanced machining PROCESSES, full FORM of ECDR is Electrochemical Drilling.
175.

Dissolution of metal containing chrome results in which of the toxic compounds?(a) Toxic chromate(b) Ammonia(c) Toxic chromate & Ammonia(d) None of the mentionedI had been asked this question during an online exam.This intriguing question comes from ECM-Environmental Impact topic in portion Electrochemical Processes of Advanced Machining

Answer»

The correct option is (C) Toxic chromate & Ammonia

Explanation: Dissolution of metal CONTAINING chromate results nitrate REDUCTION at cathode tool, which in TURN PRODUCES toxic chromate and ammonia.

176.

Which of the following processes can be done using ECM?(a) Die sinking(b) Profiling and contouring(c) Drilling and trepanning(d) All of the mentionedThis question was posed to me in class test.Query is from ECM-Applications and Micro-ECM topic in chapter Electrochemical Processes of Advanced Machining

Answer»

Correct CHOICE is (d) All of the mentioned

To elaborate: ECM can be used for die SINKING, TREPANNING, DRILLING, CONTOURING, grinding and profiling.

177.

At constant feed rates what happens to gap thickness?(a) Increases(b) Decreases(c) Becomes constant(d) None of the mentionedThis question was addressed to me during an interview.I'm obligated to ask this question of ECM-Basic Working Principles topic in division Electrochemical Processes of Advanced Machining

Answer» CORRECT option is (c) Becomes CONSTANT

The explanation is: At constant feed rate, work piece becomes STATIONARY and THUS the gap THICKNESS becomes constant.
178.

What is the value of velocity with which, electrolyte flows in the inter electrode gap?(a) >1 m/s(b) >3 m/s(c) >5 m/s(d) >10 m/sI have been asked this question at a job interview.Question is from ECM-Theory of ECM topic in division Electrochemical Processes of Advanced Machining

Answer» RIGHT CHOICE is (c) >5 m/s

Easy explanation: The velocity of the electrolytic solution must be greater than 5 m/s, in ORDER to intensify the mass and charge transfer.
179.

What are the values of current densities used in ECM?(a) 0.1 to 2 A/cm^2(b) 5 to 500 A/cm^2(c) 600 to 1000 A/cm^2(d) 1200 to 2800 A/cm^2This question was addressed to me in an online interview.This intriguing question comes from ECM topic in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct option is (b) 5 to 500 A/cm^2

For explanation: CURRENT density VALUES in ECM RANGE between 5 to 500 A/cm^2.

180.

Chemical equivalent is the ratio of which of the following factors?(a) Work piece valence to the atomic weight(b) Atomic weight to work piece valence(c) Tool valence to molecular weight(d) Molecular weight to tool valenceThis question was posed to me in a national level competition.I want to ask this question from Electro Chemical Machining-Introduction and Principle of electrolysis in division Electrochemical Processes of Advanced Machining

Answer»

The correct answer is (b) Atomic weight to work PIECE VALENCE

The best I can EXPLAIN: CHEMICAL equivalent is the ratio of atomic weight to work piece valence.

181.

When was the first significant development of ECM occurred?(a) 1920s(b) 1930s(c) 1950s(d) 1960sI had been asked this question in exam.Asked question is from Electro Chemical Machining-Introduction and Principle of electrolysis topic in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct OPTION is (c) 1950S

Easiest explanation: After the first PATENT in 1929, the first development of ECM was DONE in 1950s.

182.

In the following scientists, who was the one to introduce first patent on ECM?(a) Balamuth(b) Steve O Flawer(c) Gusseff(d) McGeoughThe question was posed to me during an interview.Question is taken from Electro Chemical Machining-Introduction and Principle of electrolysis in portion Electrochemical Processes of Advanced Machining

Answer» CORRECT option is (C) GUSSEFF

For explanation I would say: Gusseff was the one, who introduced the first patent on ECM in 1929.
183.

Which of the following parts of the body can be contaminated while using ECM?(a) Skin(b) Eyes(c) Skin & Eyes(d) None of the mentionedThe question was posed to me in a national level competition.Enquiry is from ECM-Environmental Impact topic in division Electrochemical Processes of Advanced Machining

Answer»

Right choice is (c) SKIN & Eyes

For explanation I would say: CONTAMINATION of skin and eyes may OCCUR due to electrolyte splashing and TOXIC gas RELEASE.

184.

If electro chemical machining is applied under appropriate conditions, how much amount of health dangers can occur?(a) Small amount(b) Limited amount(c) Large amount(d) Very large amountThe question was asked by my school principal while I was bunking the class.This interesting question is from ECM-Environmental Impact in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct ANSWER is (b) LIMITED amount

Easy explanation: Occupational HEALTH dangers are limited if ECM is DONE at appropriate conditions.

185.

Apparent current efficiency is due to which of the following factors?(a) Choice of wrong valence(b) Passivation of anodic surface(c) Gas evolution at anode(d) All of the mentionedThe question was asked in homework.My doubt is from ECM-Basic Working Principles in division Electrochemical Processes of Advanced Machining

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

The explanation: Current efficiency may be apparent because of choice of wrong valence, passivation of anodic SURFACE or GAS evolution at anodic surface.
186.

Compared to the tool used in ECM, how should be the work piece size?(a) Greater than(b) Smaller than(c) Same as tool(d) None of the mentionedI got this question in an interview for job.My question is based upon ECM in section Electrochemical Processes of Advanced Machining

Answer»

Correct option is (a) Greater than

To explain I WOULD say: By an oversize, WORK piece size is EXPECTED to be greater than TOOL size.

187.

How does the current pass between the two electrodes in ECM?(a) Electrolytic solution(b) Direct contact of electrodes(c) All of the mentioned(d) None of the mentionedThis question was addressed to me during a job interview.The above asked question is from ECM-Theory of ECM topic in portion Electrochemical Processes of Advanced Machining

Answer»

Correct choice is (a) Electrolytic solution

To explain: CURRENT PASSES through the solution of electrolyte, which fills the gap between the ELECTRODES.

188.

What are the feed rates used in Electrochemical drilling?(a) 0.1 to 0.6 mm/min(b) 0.6 to 1 mm/min(c) 1 to 5 mm/min(d) 6 to 15 mm/minThe question was asked by my school principal while I was bunking the class.Question is taken from Electro Chemical Drilling topic in division Electrochemical Processes of Advanced Machining

Answer»

Right choice is (c) 1 to 5 mm/min

For explanation I WOULD say: VALUE of feed rates used in Electrochemical drilling, range between 1 to 5 mm/min.

189.

What should be done to the electrolyte with solid matter?(a) Can be reused(b) Disposed off(c) No disposing is necessary(d) All of the mentionedI got this question in my homework.I need to ask this question from ECM-Environmental Impact topic in section Electrochemical Processes of Advanced Machining

Answer»

Right choice is (B) DISPOSED off

To explain I would say: The electrolyte which contain the SOLID precipitates needs to be disposed immediately, in order to avoid any DAMAGE to the ENVIRONMENT.

190.

Machining conditions leading to high accuracy are associated with ________ surface roughness and ________ productivity.(a) Greater, greater(b) Smaller, greater(c) Greater, smaller(d) Smaller, smallerI had been asked this question in quiz.My query is from ECM-Process Control in section Electrochemical Processes of Advanced Machining

Answer»

The CORRECT answer is (B) Smaller, greater

Best explanation: Accuracy is ASSOCIATED with smaller SURFACE roughness and greater machining productivity.

191.

Which of the following are the limitations of electro chemical machining?(a) Removal of hydrogen(b) Handling the electrolyte(c) Energy consumption(d) All of the mentionedI have been asked this question in an online quiz.My query is from ECM-Advantages and Disadvantages in division Electrochemical Processes of Advanced Machining

Answer»

The correct answer is (d) All of the mentioned

For EXPLANATION: Removal of HYDROGEN, HANDLING and containing the electrolyte and ENERGY consumption are some of the limitations of ECM.

192.

It is difficult to machine inner radii smaller than __________ and outer radii less than ________ in ECM.(a) 0.1 mm, 0.2 mm(b) 0.5 mm, 0.8 mm(c) 0.8 mm, 0.5 mm(d) 0.2 mm, 0.1 mmI had been asked this question at a job interview.My doubt stems from ECM-Process Characteristics in portion Electrochemical Processes of Advanced Machining

Answer»

Correct option is (c) 0.8 MM, 0.5 mm

To elaborate: It is difficult to MACHINE inner RADII < 0.8mm and OUTER radii < 0.5mm.

193.

If there is an increase in the electrolyte flow, what happens to the rate of film formation?(a) Increases(b) Decreases(c) Remains same(d) All of the mentionedI had been asked this question in quiz.My question is taken from ECM-Process Characteristics topic in portion Electrochemical Processes of Advanced Machining

Answer»

The correct option is (b) DECREASES

To ELABORATE: An increase in ELECTROLYTIC SOLUTION flow decreases the anodic product formation, which reduces the rate of film formation.

194.

Electro chemical dissolution phase starts with the movement of ions between which two components?(a) Cathode and anode(b) Cathode and power source(c) Power source and anode(d) Power source and electrolyteThe question was posed to me during an internship interview.I want to ask this question from ECM-Process Characteristics in section Electrochemical Processes of Advanced Machining

Answer»

The correct answer is (a) Cathode and anode

Easiest explanation: ECD PHASE OCCURS by the MOVEMENT of IONS between the two electrodes.

195.

State whether the following statement is true or false regarding the tools of ECM.(a) , cathodes are produced at high costs and less accurately.”(b) True(c) FalseI got this question during an interview for a job.The question is from ECM topic in chapter Electrochemical Processes of Advanced Machining

Answer»

The correct CHOICE is (B) True

The best I can explain: Using CIM, CATHODES are produced at low COSTS and more accurately.

196.

What are the other features of electrolytic solution in ECM?(a) Non toxic(b) Less erosive(c) Less viscous(d) All of the mentionedI have been asked this question in homework.Asked question is from ECM in section Electrochemical Processes of Advanced Machining

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

Easiest explanation: Electrolytic SOLUTION should be nontoxic, less viscous and less EROSIVE.
197.

Negatively charged particles (anions) move towards which electrode?(a) Anode(b) Cathode(c) Anode & Cathode(d) None of the mentionedI have been asked this question in an online interview.My question is taken from ECM-Theory of ECM in section Electrochemical Processes of Advanced Machining

Answer»

Correct answer is (a) ANODE

Explanation: Negatively CHARGED particles are DIRECTED towards the anode, which is POSITIVELY charged.

198.

Amount of mass dissolved is directly proportional to which of the following quantities?(a) Amount of electricity(b) Frequency of vibrations(c) Amplitude of oscillations(d) All of the mentionedThe question was asked during an internship interview.My question is taken from Electro Chemical Machining-Introduction and Principle of electrolysis in chapter Electrochemical Processes of Advanced Machining

Answer»

Right choice is (a) AMOUNT of electricity

To explain: Amount of MASS dissolved is directly proportional to amount of electricity and also substances’ CHEMICAL equivalent.

199.

State whether the following statement is true or false regarding the environmental impacts of ECM.(a) “In ECM, accumulation of toxic compounds is due to nitrate reduction at tool cathode.”(b) True(c) FalseI have been asked this question in class test.My doubt stems from ECM-Environmental Impact in section Electrochemical Processes of Advanced Machining

Answer»

Correct CHOICE is (a) “In ECM, accumulation of TOXIC compounds is DUE to NITRATE reduction at tool cathode.”

Explanation: When chromate containing metals dissolute, nitrate ACCUMULATE at cathode tool, which results in toxic chromate and ammonia compounds.

200.

Micro ECM is used to machine which type of parts?(a) Large parts(b) Micro parts(c) Normal sized parts(d) All of the mentionedThe question was posed to me in quiz.My question is based upon ECM-Applications and Micro-ECM in division Electrochemical Processes of Advanced Machining

Answer»

The CORRECT OPTION is (b) Micro PARTS

The explanation is: Micro ECM is used to MACHINE micro parts which can be from micro scale to mesoscale in size.