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 DEPARTMENT OF MECHANICAL ENGINEERING
UNCONVENTIONAL MACHINING PROCESSES
QUESTION BANK

UNIT-1 INTRODUCTION
Part-A (2 Marks)
1. Describe the characteristics of Unconventional Machining process. BT1
2 List the unconventional machining process which uses mechanical energy. BT1
3. Quote the necessity for unconventional machining process. BT1
4. Examine how non-traditional machining processes are classified? BT1
5. Identify the signification of unconventional machining. BT1
6. List the classification of unconventional machining. BT1
7. Distinguish traditional and non-traditional machining process. BT2
8. Summarise the types of energy are employed in non-traditional machining BT2
process.
9. Discuss LBM. BT2
10. Estimate the requirements that demand the use of advanced machining process. BT2
11. Demonstrate that conventional machining process is not so effective on soft BT3
metals like aluminium.
12.
m
Illustrate and compare various non traditional machining processes. BT3
13.
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Classify the different machining characteristics with respect to which the Non-
c
BT3

.
traditional machining process can be analysed.

a
14. Name the UCM process in which power consumption is more than others. BT4
15. Point out the chemical machining and factors by which selection of etchant is BT4
governed.
m
16. Explain UCM. a BT4

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17. Select any two demerits of UCM. BT5
18. Asses the various thermal energy based process. BT5
19. d BT6

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Generalise the various electrical energy based process.
20. Rewrite various chemical energy based process. BT6

S BT2

Part-B (16 Marks)

1. Compare the mechanical and electrical energy processes in terms of
Physical parameters, shape capabilities, process capability, and process BT4
Economy.
2. Explain the reasons for the development of Unconventional Machining
Processes. Discuss about the criteria recommended in selection of BT5
these processes
3. Integrate the items that can be considered with respect to the analysis
of economics of various non-traditional machining process? Briefly BT6
explain
4. Tabulate the comparison among various non-traditional
machining processes in terms of the following. Presentation in
the form of table is preferred. BT1
1) Pocketing operation
2) Contouring a surface
5. Describe and analyze the applicability of different processes with BT2
 different types of materials, metals, alloys and non-metals. Presentation
in the form of table is preferred
6. Label the comparison between ultrasonic machining and conventional
BT1
grinding
7. Summarise the needs for the development of unconventional
BT2
machining processes? Explain with examples
8. Classify unconventional machining processes based on basic
mechanism involved in the processes, source of energy required for the
BT3
material removal, medium for transfer of energies and type of energy
required to shape materials
9. Describe advantages of various UCM processes. BT1
10. Distinguish and contrast between various UCM processes. BT2
11. Summarise the physical parameters of various non-traditional
BT4
machining process.
12. Explain the machining characteristics of various unconventional
BT5
machining process.
13. Describe process economy of unconventional machining processes. BT3
14. Summarise the limitations of UCM processes. Justify the need of
UCM processes in today’s industries.(BT-6) BT6

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 UNIT-2 MECHANICAL ENERGY BASED PROCESSES
Part-A (2 Marks)
1. List the typical applications of ultrasonic machining. BT1
2 Define a few type of work materials for USM. BT1
3. List few desirable properties of carrier gas in AJM. BT1
4. Describe a few unique benefits of AWJM. BT1
5. Identify the transfer medium in AJM and also abrasives used. BT1
6. Label the effect of abrasive grain size on the machining rate in USM. BT1
7. Summarise a few process parameters of USM. BT2
8. Describe the principle of WJM. BT2
9. Interpret a few salient features of USM. BT2
10. Predict few applications of AJM. BT2
11. Apply the four variables that influence the metal removal rate in abrasive jet. BT3
12. Demonstrate the need for transducer in USM. BT3
13. List two applications of WJM. BT1
14. Analyse the working principle of USM. BT4
15. Explain the two applications of USM. BT4
16. Classify the Process parameters of WJM. m BT4

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17. Recommend the use of catcher in the water jet machining. BT5

.
18. Asses the characteristics of good suspension media of the USM process. BT5

a
19. Combine the types of operations that can be performed in the AJM. BT6

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20. Integrate the major elements of the USM equipment. BT6

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Part-B (16 Marks)

d
1. List the AJM process with neat sketch, write its applications and
BT1

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advantages.
2. Describe USM and conventional machining BT1
3.
S
Describe a schematic layout of AJM and explain its operational
characteristics. What are the methods adopted to have an effective BT1
control over the mass flow rate of the abrasive?
4. Summarise the process of the WJM and the process parameters BT2
5. Describe the methods of generating the ultrasonic and characteristics
of the various types of tool holders and the tool feed mechanism in BT2
USM process and the process parameters
6. Demonstrate the USM, WJM, and AJM in terms of process capabilities
BT3
and limitations.
7. Illustrate the effect of the following parameters on the MRR and
surface finish in USM 1)amplitude& frequency 2)abrasive size BT3
3)concentration of abrasive 4)material hardness
8. Analyse the process of AWJM and the process parameters. BT4
9. Assess the various Process parameters of WJM & AJM BT5
10. Compose the functions of the transducer and horns used in USM. List
BT6
the tool materials
11. How are ultrasonic vibration generated in USM process? BT5
12. Make the comparison between USM and conventional grinding with
BT6
suitable example.
13. Discuss about the control of quality in USM and capabilities of USM. BT2
14. Briefly explain the effect of operating parameters on material removal
BT1
rate. List of applications of USM.

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 UNIT -3 ELECTRICAL ENERGY BASED PROCESSES
Part-A (2 Marks)
1. List the purpose of dielectric in EDM. BT1
2 Define the range of pulse duration and current in EDM. BT1
3. Describe the recent developments in EDM process. BT1
4. Describe the properties required for dielectric fluid for EDM. BT1
5. Identify the applications and limitations of EDM. BT1
6. Label the difference between wire cut EDM and EDM. BT1
7. Summarise the function of servo control system in EDM. BT2
8. Describe the process capabilities of EDM process. BT2
9. Interpret the types of tool materials used in EDM. BT2
10. Predict the functions of dielectric medium used in EDM. BT2
11. Classify the types of power generator circuits used in EDM. BT3
12. Demonstrate recast layer with reference to the EDM. BT3
13. Assess the influence of current in MRR in EDM process. BT3
14. Analyse the functions of adaptive control used for EDM. BT4
15. Separate a few varieties of power supply circuits commonly used in electrical BT4
discharge machining.

m
16. Explain the principle of operation of wire-cut EDM process. BT4
17. Assess the ways of gap-flushing used in EDM.
c o BT5

.
18. Decide the categories into which the variety of power supply circuits in EDM BT5
process can be classified.
a
m
19. Combine the function of servo mechanism in EDM process. BT6

a
20. Integrate the desirable properties for dielectric fluid. BT6

yn
d
Part-B (16 Marks)t u
1. S
Describe the process of Wire cut EDM and list its advantages and
BT1
disadvantages, applications, limitations.
2. Examine the process of EDM, its process parameters, advantages,
BT1
disadvantages and applications.
3. Tabulate the servo system used to control the feed rate in EDM
BT1
process.
4. Predict the three types of spark generators used in EDM and describe
BT2
them.
5. Summarize the recent developments in EDM process and state the
BT2
limitations of EDM process.
6. Complete how MRR and quality is controlled in EDM process? BT3
7. Illustrate the classification and characteristics of various spark erosion
BT3
generators.
8. Explain the different types of control circuits used in EDM process. BT4
9. Grade the various types of flushing system employed in EDM process. BT5
10. Create the basic requirements of tool materials in EDM process? Name BT6
 any 4 tool Materials.
11. How will you analyse optimization of metal removal rate in
EDM process? What are the steps that are to be adopted in
sequences while applying Linear programming technique to BT6
optimize MRR in EDM process?

12. Compare EDM and Wire Cut EDM process. In what ways wire cut
BT1
EDM process is best over EDM process? Justify.
13. Explain the brake down mechanism in EDM process. BT4
14. Briefly explain various types of dielectric fluid and its functions in
BT6
EDM process.

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UNIT 4. CHEMICAL AND ELECTROCHEMICAL ENERGY BASED PROCESS
Part-A (2 Marks)
1. List the Principle of ECM. BT1
2 Define the Electrolytes used in ECM. BT1
3. List the Tool materials used in ECM. BT1
4. Describe the Process parameters of ECM. BT1
5. Identify the Limitations of ECM. BT1
6. Label the Functions of electrolyte in ECM. BT1
7. Summarise the Applications of ECM. BT2
8. Express the Advantages of chemical machining. BT2
9. Discuss Self adjusting feature in ECM. BT2
10. Discuss the etch factor. BT2
11. Discover Advantages of ECM. BT3
12. Experiment the Difference between electroplating and ECM. BT3
13. Classify the Process parameters of ECG. BT3
14. Point out the application of electro chemical honing. BT4
15. Infer CHM. BT4
16. Explain etchant. BT4
17. Summarise maskant. BT5
18. Compare the two etchants. BT5
19. Compose two maskants. m BT6
20. Generalise techniques of applying maskant.
c o BT6

.
Part-B (16 Marks)
a
1. m
a
Quote ECM process with sketch and discuss influences of process
BT1

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parameters in machining output.
2. Name ECG process with sketch and state the process capabilities and
BT1
d
applications.

tu
3. Describe the characteristics of electrolyte used in ECM, factors
BT1
influencing the selection of maskants in chemical machining process
4.
S
Predict the MRR by ECG comprise. What are the functions of abrasive
particles?
BT2
5. Associate type of material can be grounded in ECG? BT2
6. Relate about the effect of high temperature and pressure of the
BT3
electrolyte on the ECM process.
7. Demonstrate the working principle of chemical machining. What are
the factors on which the selection of a resist for use in chemical BT3
machining.
8. Select ECH process with sketch and discuss the applications. BT4
9. Explain the process parameters, MRR and surface finish in CHM. BT5
10. Describe the following in ECM process i. advantages ii. Disadvantages
BT4
iii. Application.
11. An iron work piece is subjected to ECM using copper electrode and
NaCl (specific resistant = 5.0 ohm- cm) as electrolyte the supply
voltage is 16V D.C and current applied is 600A. IF a gap between the BT6
tool and work piece is 0.05 cm, calculate following i. machining rate ii.
electrode feed rate
12. Calculate amount of current required the iron is subjected to ECM
process. The metal removal rate of iron is 4cm3/min. assuming atomic BT6
weight iron N = 56 Kg, valancy n=2, Density of iron ρ =7.87g/cm3.
13. Explain the requirement of tool material for ECM process. Write the
BT5
commonly tool materials.
14. Plan the process parameters, MRR and surface finish in ECM. BT6

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 UNIT 5 THERMAL ENERGY BASED PROCESSES
Part-A (2 Marks)
1. List the Limitations of EBM. BT1
2 Define transferable arc in plasma machining. What is its use? BT1
3. What is the Acronym of LASER? BT1
4. Name the Gases used in the plasma arc machining. BT1
5. Quote deflection coil provided for EBM. BT1
6. Examine the Principle of LBM. BT1
7. Express electron beam. BT2
8. Contrast LBM and EBM. BT2
9. Discuss Commonly used gas mixture in PAM. BT2
10. Express the Characteristic of laser beam. BT2
11. Relate EBM is different from PAM. BT3
12. Distinguish vacuum and non-vacuum EBM. BT3
13. Distinguish EBM and LBM. BT3
14. Divide the uses of vacuum and non-vacuum EBM. BT4
15. Infer functions of water muffle in PAM. BT4
16. Classify the population inversion between energy levels in LBM. BT4
17. Grade the principle of PAM. BT5
18. Conclude, why a high vacuum is created in the EBM apparatus. BT5
19. Design the parameters of PAM.
m BT6
20. Invent the advantages of LBM.
c o BT6

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Part-B (16 Marks) a
m
1.
a
Describe Laser beam machining and drilling with sketches.

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BT1
2. Describe the Process of PAM with neat sketch. BT1
3.
d
Discuss the Process parameters of EBM and influence on machining

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BT1
quality.

S
4. Summarise EBM with neat sketch and the process parameters BT2
5. Describe the Process parameters of PAM and influence on machining
BT2
quality
6. Apply the Process capabilities of PAM. BT3
7. Demonstrate the Thermal features of LBM. Discuss the performance
BT3
of various types of lasers
8. Analyse non transferred and transferred mode of PAM? Explain the
BT4
mechanism of material removal in PAM.
9. Assess the factors that influence the quality of circuit in PAM. BT5
10. Formulate laser. How it is used to machining the materials? BT6
11. Explain the following in LBM process i. Advantages ii. Disadvantages
BT4
iii. Application
12. Describe the Process parameters of EBM and influence on machining
BT2
quality.
13. Compare the working principle of EBM and LBM with suitable sketch. BT1
14. Explain the control of following parameter in EBM. i) Current ii.) Spot
diameter iii) Focus distance of magnetic lens. (BT-4) BT4
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