R.M.K.

ENGINEERING COLLEGE
RSM Nagar, Kavaraipettai – 601 206

Question Bank for the Units – I to V

SE00 7th Semester – B.E. / B.Tech.

BR00 Mechanical Engineering

SU00 ME8073– UNCONVENTIONAL MACHINING PROCESSES

CO1# Explain the need for unconventional machining processes and various mechanical energy based processes K2

CO2# Discuss various thermal energy based unconventional machining processes. K2

CO3# Discuss various electrical energy based unconventional machining processes. K2

CO4# Summarize various chemical and electro-chemical energy based unconventional machining processes. K2

CO5# Explain various nano abrasives based unconventional machining processes. K2

CO6# Distinguish various recent trends based unconventional machining processes K2

Part-A (10 x 2 = 20 Marks) Stand

K
CO ard
Level S/A

1. Describe the characteristics of Unconventional Machining process. K2 CO1 S

1. State the necessity for unconventional machining process. K2 CO1 S

1. State the drawbacks of non-traditional machining process. K1 CO1 A

1. Why unconventional machining processes are not economic for soft

K3 CO1 S
materials like aluminium?

1. List few type of work materials machined by Ultrasonic Machining. Why? K2 CO1 A

2. Identify the transfer medium in Abrasive Jet Machining and also abrasives
K1 CO1 S
used.

2. Can we reuse abrasives used in AWJM? Justify K2 CO1 S

2. What is the function of catcher in WJM? List its types. K2 CO1 S

2. Write the differences between the Magneto-strictive and Piezo-electric

K2 CO1 S
transducer?

2. What is nodal point clamping in USM process? K3 CO1 A

3. Why, less metal is removed from tool when compared to workpiece in K2 CO3 S
EDM process.
3. What are the prime requirements of tool material in EDM? Name some of
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the tool material.

3. What is overcut in EDM process? How it is affected by current and

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frequency?

3. State the advantages of WEDM process over ordinary EDM? K2 CO3 S

3. How spot diameter is controlled in LBM process? K3 CO2 S

4. Can you deflect the laser beam? Justify. K2 CO2 S

4. Why vacuum is needed in EBM process? K3 CO2 S

4. How electron beam is controlled in EBM process? K2 CO2 S

4. Why vacuum is needed in EBM process? K2 CO2 S

4. What is plasma? K1 CO2 A

5. State the principle of chemical machining process. K1 CO4 A

5. Distinguish between electrochemical machining and electro plating

K2 CO4 S
process.

5. What are the materials used for tool in ECM process? K2 CO4 A

5. State the functions of electrolyte fluid used in ECM process. K1 CO4 A

5. What is the function of etchants used in chemical machining K1 CO4 S

6. Write a short note on ECG wheel. K2 CO4 A

6. What are the advantages of ECG over conventional grinding process? K2 CO4 S

6. Write the principle of ECH Process? K1 CO4 A

6. Write the limitations of ECM process. K2 CO4 A

6. Write a short note on ECG wheel. K2 CO4 A

7. What are all the abrasives used in Abrasive Flow Machining? K1 CO5 A

7. Write the classification of Abrasive Flow Machining. K1 CO5 A

7. State the functions of polymer carriers in Abrasive Flow Machining. K1 CO5 A

7. State the advantages of Ultrasonic Assisted Abrasive Flow Machining

K3 CO5 A
(UAAFM) process.

7. State the principle of Chemo-Mechanical Polishing. K1 CO5 A

8. What is MAFB in Magnetic Abrasive Finishing Process? K2 CO5 S

 8. State the effect of flux density in Magnetic Abrasive Finishing Process? K3 CO5 S

8. List the advantages of Magneto Rheological Finishing Process. K2 CO5 A

8. Write the significance of Magneto Rheological Abrasive Flow Finishing

K3 CO5 S
Process.

8. What is CIP in Magneto Rheological Finishing Process? K3 CO5 A

9. List few recent advancements in AJM process K3 CO6 A

9. List the types of operations that can be performed in the Abrasive Jet
K2 CO6 A
Machining.

9. State the effect of rotational speed of tool on MRR in die sinking EDM
K3 CO6 S
Process?

9. List the major applications of PAM process. K2 CO2 A

9. Discuss Commonly used gas mixture in PAM. K1 CO2 A

10. Write the advantages of EDG compared to conventional grinding K3 CO6 S

10. Compare ECM process with Electroplating process. K3 CO3 A

10. State the advantages of EBM over LBM K3 CO2 A

10. What are the factors affecting MRR in MAF process? K2 CO5 A

10. Write the advantages of MRAFF process compared to MRF process. K3 CO5 S

Part – B ( 5 x 13 = 65 Marks)

11.a. Classify the unconventional machining processes based on type of energy

K2 CO1 A
employed, MRR, transfer media, and energy source used.

11.a. Draw a layout of AJM process and briefly discuss the metal removal
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mechanism by stating the functions of their major components.

11.a. Discuss the process parameters of AJM process on the process

K3 CO1 S
characteristics with the aid of graphs.

11.a. Explain briefly, how the various parameters influences the metal removal
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rate in AJM process.

11.a. Discuss the four sub-systems of AJM process with schematic diagram and
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briefly discuss the effects of process parameters.

11.b. Describe the process principle and basic equipment of WJM process with a
K3 CO1 A
neat sketch.

11.b. Explain in detail, the working principle of USM process with schematic
K2 CO1 A
diagram.
11.b. Describe the various tool feeding mechanism and the type of transducers
K3 CO1 S
used in USM process with a neat sketch.

11.b. Explain the AWJM process with a neat sketch. Write its merits and
K2 CO1 A
demerits.

11.b. Discuss the effect of pressure, SOD, flow rate, jet velocity, density and
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viscosity of fluid on process characteristic of WJM suitable graph.

12.a. With a neat sketch, explain the working of EDM process. Also writes its
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merits and demerits

12.a. (i) Discuss the essential properties of dielectric fluid used in EDM process.
(7) K3 CO3 A
(ii) Explain the various flushing techniques used in EDM process.(6)

12.a. Discuss the effect of process parameters that affects the metal removal rate in
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EDM process.

12.a. What is the role of pulse generator in EDM process? Explain any two type
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of pulse generator in detail.

12.a. Explain the general arrangement of Wire Electrical Discharge Machining

K2 CO3 A
process with a neat sketch.

12.b. Explain the components and working of LBM with a sketch. Also, write its
K2 CO2 A
characteristics and process capabilities.

12.b. Discuss the various process variables affecting the machining rate of LBM K2 CO2 S

12.b. Explain the principles, machining system, process capabilities,

K3 CO2 A
applications and advantages of Plasma Arc Machining with neat sketch

12.b. Discuss with a neat sketch, working principle, construction and

K2 CO2 A
applications of EBM

12.b. Elaborate the effect of process parameters that affects the process
K2 CO2 S
characteristics of EBM process.

13.a. With the help of simple diagram, explain the working of Chemical
K2 CO4 A
Machining process.

13.a. Discuss the effect of process parameters that affects the metal removal
K3 CO4 S
rate in ECM process.

13.a. Discuss in detail, the effect of process parameters of Electro Chemical

K2 CO4 S
machining process with suitable graphs.

13.a. Explain the principles, machining system, process capabilities, applications and
K2 CO4 A
advantages of ECM process.

13.a. Briefly explain the working principle, construction and applications of K2 CO4 A
ECM process with neat sketches.
13.b. Explain the working of ECG process with a schematic diagram? Discuss the
K2 CO4 A
effect of process parameters on MRR.

13.b. (i) Explain the various chemical reactions occurred in ECM process.(7)
K3 CO4 S
(ii) Compare the ECG process with conventional grinding process. (6)

13.b. (i) Describe the construction and working of Electro Chemical Honing
process.(7) K2 CO4 A
(ii) Discuss the essential requirements of electrolytic fluid.(6)

13.b. (i) Explain the working of ECH process with a schematic diagram.(7)
K2 CO4 A
(ii) Describe the main components of ECG process in detail.(6)

13.b. (i) Discuss the essential requirements of electrolyte fluid.(6)

K2 CO4 A
(ii) Explain the general arrangement of an ECH process with a neat sketch.(7)

14.a. Explain the basic components and working of different type of AFM
process with a sketch. Also, write its characteristics and process K2 CO5 S
capabilities.

14.a. Discuss the various process variables affecting the machining rate of AFM
K3 CO5 S
process in detail.

14.a. Explain the principles, machining system, process capabilities,

applications and advantages of any two type of Abrasive Flow Machining K3 CO5 A
process with neat sketches.

14.a. Discuss with a neat sketch, working principle, construction and applications of
K2 CO5 A
Chemo-Mechanical Polishing.

14.a. Elaborate the effect of process parameters that affects the process
K3 CO5 S
characteristics of AFM process.

14.b. Explain the main components and working principle of MAF process with
K2 CO5 A
a sketch. Also, write its merits and demerits.

14.b. Discuss the effect of control parameters that affects the process
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characteristics of MAF process.

14.b. Discuss the working principle and construction of MRF process with neat
K2 CO5 A
sketches.

14.b. Describe the construction and working of Magneto Rheological Finishing

K2 CO5 S
Process with suitable diagrams.

14.b. Explain the principles, machining system, process capabilities, and

K2 CO5 S
applications of Magneto Rheological Abrasive Flow Finishing process.

15.a. Describe any two recent developments adopted in EDM process with
K3 CO6 S
suitable diagram and explain its significance.

15.a. Briefly explain the effect of process parameters of USM process on K3 CO6 S
machining characteristics.
15.a. Explain the effect of wire tension, wire diameter, wire traverse speed and
frequency on kerf width, overcut, MRR and HAZ in recent developed 5-axis K4 CO6 S
precision Wire-EDM process.

15.a. Explain the Thermal features of LBM process. Discuss the performance of
K3 CO6 A
various types of lasers

15.a. Describe any two recent developments implemented in PAM process and
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explain its impact on process characteristics.

15.b. Compare the ECM process with EDM process in relates with working
principle, energy transfer media, process capabilities, applications and K3 CO4 S
limitations with necessary diagrams.

15.b. Discuss any two recent developments made in AFM process with neat
K2 CO6 A
sketches.

15.b. Describe the process of Ultrasonic Assisted Abrasive Flow Machining

K2 CO6 A
(UAAFM) process in detail.

15.b. Describe the construction and working of Rotational Abrasive Flow Finishing
K2 CO6 S
(R-AFF) process.

15.b. Compare the ECM process with Chemo Mechanical Polishing (CMP)
process in relates with working principle, energy transfer media, process K3 CO6 S
capabilities, applications and limitations.

Part – C ( 1 x 15 = 15 Marks)

16.a. Explain the reasons for the development of unconventional machining

process. Discuss about the criteria recommended in selection of these K3 CO1 A
process

16.a. Discuss any four case studies to justify the unconventional machining is
K4 CO1 S
essential when compared to conventional type machining

16.a. Explain the factors, considered during the selection of appropriate

K3 CO1 A
unconventional machining processes for a given job.

16.a. Compare and contrastthe AJM process with EDM process based on physical
K3 CO1 S
parameters, shape to be machined, process capabilities and process economy.

16.a. (i) Explain how the stratified wire works and discuss the recent
development in wire cut EDM. (9)
K3 CO6 S
(ii) Explain the differences between EDM and Wire cut EDM with an
example. (6)

16.b. How intricate designs on glass work-piece is carried out? Explain in detail
K4 CO6 S
with suitable example.

16.b. Compare the MRF process with Lapping process and Honing process in K4 CO5 A
relates with working principle, working medium, process capabilities,
 applications and limitations.

16.b. Discuss the process of Drill Bit Guided Abrasive Flow Finishing (DBG-AFF)
K3 CO6 A
process and explain its specific significance.

16.b. How the EDM recast layer can be removed using AFM Process. Explain with
K3 CO6 S
suitable examples.

16.b. Which UCM process is best suitable for making cavities in hard and brittle
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materials? Justify with suitable application