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Introduction to Mechanical Micro Machining

Assignment- Week 1
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Initial diameter in turning operation is 50 mm and depth of cut is 2 mm. What will be the final
diameter after 2 passes?
a) 46 mm
b) 42 mm
c) 48 mm
d) 44 mm

Correct Answer: (b)

Detailed Solution:

Depth of cut where n is number of passes

Final diameter= Initial diameter – 2n * (depth of cut) = 50- 2*2*2= 42 mm

QUESTION 2:

The size of an object is 20 mm and its relative accuracy is 10-5, then its tolerance will be
a) 0.0002 mm
b) 0.0001 mm
c) 0.0004 mm
d) 0.00005 mm

Correct Answer: (a)

Detailed Solution: Tolerance = Relative accuracy * Size = 10-5 * 20 = 0.0002 mm

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QUESTION 3:

Part programs are processed by

a) Driving system
b) Feedback system
c) Machine Control Unit (MCU)
d) Machine tool

Correct Answer: (c)

Detailed Solution:
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QUESTION 4:

Which of the following is a mass containing process?

a) Welding
b) Turning
c) Milling
d) Casting

Correct Answer: (d)

Detailed Solution:

QUESTION 5:

Which of the following process does not use thermal energy to remove material?
a) EDM
b) LBM
c) EBM
d) AJM

Correct Answer: (d)

Detailed Solution: Abrasive jet machining removes material by high velocity impact of abrasive
particles.
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QUESTION 6:

A component has size of 200 mm x 200 mm x 0.1 mm. Geometry of component is considered as
a) 1-D
b) 2-D
c) 2.5-D
d) 3-D

Correct Answer: (c)

Detailed Solution: As the dimension in third axis is very small as compared to other two
dimensions. This type of geometry is 2.5D geometry.

QUESTION 7:

In general, what is the component size in mechanical micro machining?

a) 1-1000 nm
b) 1-1000 µm
c) 1-1000 mm
d) 1-1000 m

Correct Answer: (b)

Detailed Solution:
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QUESTION 8:

Which of the control system has feedback device?

a) Open loop control system
b) Closed loop control system
c) Both (a) and (b)
d) None of these

Correct Answer: (b)

Detailed Solution: Closed loop control system works on feedback device.

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QUESTION 9:

Which of the following code is used for linear movement?

a) G01
b) G02
c) G03
d) G04

Correct Answer: (a)

Detailed Solution:
G01- Linear movement
G02- Circular movement in clockwise direction
G03- Circular movement in anticlockwise direction
G04- Dwell

QUESTION 10:

If size of an object is doubled while feature tolerance remains same. What will be the change in
relative accuracy?
a) Gets doubled
b) Gets halved
c) Becomes 4 times
d) Remains constant

Correct Answer: (b)

Feature tolerance
Detailed Solution: Relative accuracy =
Size
If size gets doubled then relative accuracy will be halved.

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 2
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Perimeter is scaled with length at

a) l
b) l2
c) l3
d) l4

Correct Answer: (a)

Detailed Solution:
Perimeter is directly proportional to length.
Hence, perimeter is scaled with length at l.

QUESTION 2:

Which one of the following is scaled with length at l5

a) Area
b) Surface tension
c) Mass moment of inertia
d) Mass

Correct Answer: (c)

Detailed Solution:
Mass moment of inertia is directly proportional to mass and square of radius.
Hence, mass moment of inertia is scaled with length at l5.
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QUESTION 3:

A cuboid with dimensions 100 mm x 200 mm x 300 mm is scaled down to 1 mm x 2 mm x 3 mm.

How much will be the total surface area to volume ratio after scaling?
a) Increases 50 times
b) Increases 100 times
c) Decreases 50 times
d) Decreases 100 times

Correct Answer: (b)

Detailed Solution:
𝑆 2 𝑙𝑏 𝑏ℎ 𝑙ℎ
𝑉 𝑙𝑏ℎ
𝑆 2 100 ∗ 200 200 ∗ 300 100 ∗ 300 11
𝐵𝑒𝑓𝑜𝑟𝑒 𝑠𝑐𝑎𝑙𝑖𝑛𝑔,
𝑉 100 ∗ 200 ∗ 300 300
𝑆 2 1∗2 2∗3 1∗3 11
𝐴𝑓𝑡𝑒𝑟 𝑠𝑐𝑎𝑙𝑖𝑛𝑔,
𝑉 1∗2∗3 3
11
𝐴𝑓𝑡𝑒𝑟 𝑠𝑐𝑎𝑙𝑖𝑛𝑔 3 100
𝐵𝑒𝑓𝑜𝑟𝑒 𝑠𝑐𝑎𝑙𝑖𝑛𝑔 11
300
Total surface area to volume ratio after scaling increase 100 times.
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QUESTION 4:

Which of the following is correct sequence as a practice to achieve good results during machining?
a) Test Inspect  Analyze  Adjust
b) Inspect Test  Analyze  Adjust
c) Test  Analyze Inspect  Adjust
d) Inspect  Analyze  Test  Adjust

Correct Answer: (a)

Detailed Solution:
The correct sequence is to first test thereafter inspect for possible problems then analyze the
problem and at last adjust accordingly.

QUESTION 5:

With reference to scaling laws, consider the following statements

I. At small scale gravitational force becomes less effective
II. At small scale inertial force becomes more effective
III. At small scale electrostatic forces becomes more effective

Which of the above statements are correct?

a) Only I and II
b) Only II and III
c) Only I and III
d) I, II and III

Correct Answer: (c)

Detailed Solution:
At small scale, gravitational force and inertial force become less effective whereas surface tension
force, electrostatic force and Van der Waals force become more effective.
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QUESTION 6:

A Euler column shown in figure below is scaled down proportionally (L and b) from 3 mm to 0.1
mm. Its critical buckling strength ignoring end conditions

a) Increases 30 times
b) Decreases 30 times
c) Increases 900 times
d) Decreases 900 times

Correct Answer: (d)

Detailed Solution:
Critical strength of a Euler column is directly proportional to square of the length.
𝑃 ∝𝑙
It is decreased to 900 times its value before scaling down.
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QUESTION 7:

A square beam as shown in figure below is scaled down proportionally (L and b) from 20 mm to X
mm. Under the self-weight, deflection decreases to 2500 times the value before scaling. What will
be the value of X?

a) 0.008
b) 0.4
c) 0.004
d) 0.2

Correct Answer: (b)

Detailed Solution:
Under self-weight, deflection is directly proportional to square of the length.
𝛿∝𝑙
A square beam must be scaled down proportionally (L and b) from 20 mm to 0.4 mm.
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QUESTION 8:

When the radius of the pipe is scaled down from 2 mm to 0.1 mm, pressure drop per unit length
(∆p/L)

a) Increases 20 times
b) Decreases 20 times
c) Increases 400 times
d) Decreases 400 times

Correct Answer: (c)

Detailed Solution:
Pressure drop per unit length (∆p/L) is inversely proportional to square of radius.
∆𝑝
∝𝑎
𝐿
It is increased to 400 times its value before scaling down.
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QUESTION 9:

In a metal cutting operation, uncut chip thickness is tu and chip thickness is tc then chip thickness
ratio is given by
a) tu / tc
b) tc / tu
c) (tu / tc)2
d) (tc / tu)2

Correct Answer: (a)

Detailed Solution:
𝑡
𝐶ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜
𝑡

QUESTION 10:

Which of the following statement/s is/are correct about micro cutting?

Statement 1: High cutting temperature
Statement 2: Small uncut chip thickness
a) Only statement 1 is correct
b) Only statement 2 is correct
c) Both statements are correct
d) Both statements are incorrect

Correct Answer: (b)

Detailed Solution:
Micro-cutting operation has small uncut chip thickness and that results in low cutting temperature.

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 3
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Which of the following is correct when chip thickness is smaller than cutting edge radius?
a) Positive rake angle
b) High productivity
c) Either (a) or (b)
d) Neither (a) nor (b)

Correct Answer: (d)

Detailed Solution:
When chip thickness is smaller than cutting edge radius then negative rake angle and low
productivity are prominent.

QUESTION 2:

Which of the following statement/s is/are correct about micro machining?

Statement 1: Uncut chip thickness is proportionally just as large as the cutting edge radius
Statement 2: Cutting force will easily exceed bending strength of tool
a) Only statement 1 is correct
b) Only statement 2 is correct
c) Both statements are correct
d) Both statements are incorrect

Correct Answer: (c)

Detailed Solution:
In micro machining, uncut chip thickness is just as large as cutting edge radius. It is easier to
exceed bending strength of the tool in conventional machining.
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QUESTION 3:

Match the following and choose correct option

A Ploughing I Similar to grinding
B Rubbing II Lowest rake angle on negative size
C Shearing III Displacement of material by plastic upheaval
D Extrusion IV Significant friction force

a) A-I, B-IV, C- III, D-II

b) A-IV, B-I, C- II, D-III
c) A-III, B-IV, C- II, D-I
d) A-II, B-I, C- IV, D-III

Correct Answer: (c)

Detailed Solution:
Ploughing- Displacement of material takes place by plastic upheaval
Rubbing- Significant friction force
Shearing – Lowest rake angle on negative side
Extrusion- Similar to grinding in material removal mechanism
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QUESTION 4:

How low productivity can be countered in micro milling?

a) Increasing RPM
b) Decreasing RPM
c) Increasing depth of cut
d) Decreasing depth of cut

Correct Answer: (a)

Detailed Solution:
Low productivity can be countered by increasing RPM to a very high value.

QUESTION 5:

Which of the following gets affected during micromachining of anisotropic material?

a) Cutting forces
b) Surface finish
c) Energy requirements
d) All of the above
e) Only (a) and (b)
f) Only (b) and (c)

Correct Answer: (d)

Detailed Solution:
In micromachining of anisotropic material, cutting forces, surface finish and energy requirements
get affected.
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QUESTION 6:

Which of the following mechanism is shown in figure below?

a) Shearing
b) Extrusion
c) Ploughing
d) Rubbing

Correct Answer: (b)

Detailed Solution:
This is an extrusion mechanism in which material is extruded at tool edge rather than shearing
deformation.
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QUESTION 7:

Which of the following criteria is related to elastic recovery during material removal? Here h is
uncut chip thickness and hm is minimum uncut chip thickness
a) h < hm
b) h = hm
c) h > hm
d) Both (a) and (b)

Correct Answer: (d)

Detailed Solution:
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QUESTION 8:

Match the following and choose correct option

A Necking I

B Inclusion II

C Fracture III

D Nucleation IV

a) A-IV, B-I, C- II, D-III

b) A-II, B-I, C- IV, D-III
c) A-IV, B-III, C- II, D-I
d) A-II, B-III, C- IV, D-I

Correct Answer: (b)

Detailed Solution:
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QUESTION 9:

Which of the following combination of planes in silicon is weakest and strongest respectively?
a) 100 and 110
b) 101 and 110
c) 100 and 111
d) 101 and 111

Correct Answer: (c)

Detailed Solution:
In silicon 100 is the weakest plane whereas 111 is the strongest plane.

QUESTION 10:

Which of the following is correct dimensional formula of specific cutting energy?

a) M1 L1 T1
b) M1 L-1 T-2
c) M1 L-2 T-3
d) M1 L-1 T1

Correct Answer: (b)

Detailed Solution:
Unit of specific cutting energy is J/mm3 or N-m/mm3
∗
So its dimensional formula will be 𝑀𝐿 𝑇 .

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 4
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Specific cutting energy is defined as

a) Energy consumed in removing unit volume of workpiece material
b) Percentage of energy spend in material removal by ploughing
c) Ratio of material removal rate and RMS value of cutting force
d) Ratio of material removal rate and mean value of cutting force

Correct Answer: (a)

Detailed Solution:
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QUESTION 2:

When uncut chip thickness is less than the cutting edge radius of the cutting tool,

a) Cutting force reduces with respect to reduction in uncut chip thickness

b) Ploughing forces will become negligibly small
c) Specific energy increases
d) Wavy like burrs are formed on the top edge

Correct Answer: (c)

Detailed Solution:
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QUESTION 3:

Plastic flow around the blunt cutting edge will,

a) Enhance the surface quality of side walls
b) Reduces material deposition on tool surface
c) Increase cutting force and specific energy
d) Reduce chatter and tool vibrations

Correct Answer: (c)

Detailed Solution:
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QUESTION 4:

Deburring operations to remove burrs in micro machining is challenging due to,

a) Thermal hardening of the burrs
b) Lack of defects inside the burrs
c) Deburring may deform the machined micro features
d) Deburring may increase the surface roughness

Correct Answer: (c)

Detailed Solution:
As the micro features machined are thin and prone to deformation, deburring forces may make
shape distortion to the small features. Therefore, using conventional deburring techniques for burr
removal is very challenging.
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QUESTION 5:

Burrs formed from bending of the chip is known as

a) Tear burr
b) Fracture burr
c) Poisson burr
d) Rollover burr

Correct Answer: (d)

Detailed Solution:
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QUESTION 6:

In up milling side, the burr formation is due to

a) Material softening
b) Chip tearing
c) Material bulging
d) Thermal cracking

Correct Answer: (c)

Detailed Solution:
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QUESTION 7:

Which statement is correct?

a) Burr height increases as the number of cutting edges increase in brass
b) Higher cutting velocity will result in lower burr height in steel
c) Coating the tool with a harder material will increase the burr formation in polymers
d) Cutting fluid velocity has a severe impact on the burr height in all materials

Correct Answer: (b)

Detailed Solution:
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QUESTION 8:

Powder blasting using white fused alumina is used as a,

a) Micromachining method for metal matrix composites
b) Surface hardening process for steel
c) Polishing method for soft polymers
d) Deburring method for brass

Correct Answer: (d)

Detailed Solution:
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QUESTION 9:

Medium frequency components in a surface texture profile is called?

a) Peaks

b) Waviness

c) Roughness

d) Pitch

Correct Answer: (b)

Detailed Solution:
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QUESTION 10:

For a high amplitude high wavelength surface profile, which one of the measuring methods is used?
a) AFM

b) Optical type

c) Stylus type

d) Image processing

Correct Answer: (c)

Detailed Solution:

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 5
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

As the material experiences more elastic recovery during machining, surface roughness will

a) Increase
b) Decrease
c) Increase in brittle materials and decrease in ductile materials
d) Increase in isotropic materials and decrease in anisotropic materials

Correct Answer: (a)

Detailed Solution:
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QUESTION 2:

A vacuum holder helps to,

a) Evacuate the microchips by sucking it away time to time

b) Hold the cutting fluid at the machining zone for a longer period
c) Handle the micro components without making any permanent deformations
d) Hold the tool monitoring systems at position for online monitoring

Correct Answer: (c)

Detailed Solution:
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QUESTION 3:

Compared to conventional machine tools, micromachining center should have,

1. Higher stiffness to damp the vibrations
2. Higher degree of straightness to the machine bed
3. Sophisticated temperature control
4. Open loop feedback system
5. Special vibration damping systems

a) 1,2,3, and 5

b) 2,3,4, and 5

c) 1,2,3 and 4

d) 2 and 3

Correct Answer: (a)

Detailed Solution:
Machine tools for micro machining demand a closed loop feedback system for accurate position
control.
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QUESTION 4:

Dirt in the grating scale of the optical encoder will result in

a) Tool runout errors

b) Variation in cutting velocity
c) Variation in machine stiffness
d) Positioning errors

Correct Answer: (d)

Detailed Solution:
Dirt in the grating scale will result in error in the position measurement.

Ref: www.heidenhain.us
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QUESTION 5:

Tool condition monitoring is the process of,

a) Setting the workpiece surface zero point with respect to the tool height

b) Setting the shortest tool path for giving maximum tool life

c) Monitoring of the burr profile to identify optimum tool feed

d) Measuring tool dimensions to ensure the cutting tool is not broken

Correct Answer: (d)

Detailed Solution:
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QUESTION 6:

Which of the following is NOT TRUE regarding a machine tool structure for micromachining?

a) It should have low structural loop stiffness

b) It should have good damping property

c) It should have low thermal deformations

d) It should have symmetry and closed loop configuration

Correct Answer: (a)

Detailed Solution:
Machine tools must have high structural loop stiffness to damp vibrations in the structure.
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QUESTION 7:

Bi-directional repeatability of the machine tool is affected by,

a) Environmental conditions
b) Spindle speed variations
c) Backlash errors
d) Type of lubricating system used in machining

Correct Answer: (c)

Detailed Solution:
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QUESTION 8:

In a CNC program, the tool path is defined that the tool will move 10.3453 mm in X+ direction and
2.2342 mm in Y- direction from origin. If the resolution of the machine tool is 10 µm, what will be
the actual tool position at the final point?

a) (10.3343, -2.2332)
b) (10.34, -2.23)
c) (2.3363, -10.2352)
d) (10.3, -2.3)

Correct Answer: (b)

Detailed Solution:
As the resolution is 10 µm, the machine tool cannot achieve a positional accuracy above that.
Therefore, the decimal places after 10 µm is irrelevant.
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QUESTION 9:

Resolution of the machine tool does NOT depend on

a) Resolution of the feed drive

b) Resolution of the Encoders
c) Backlash in feed drives
d) Type of cutting tool used

Correct Answer: (d)

Detailed Solution:
Type of cutting tool is not related to resolution of the machine.
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QUESTION 10:

Index grating linear scale is the part of,

a) Tool monitoring system

b) Optical encoder

c) Machine structure

d) Spindle motor

Correct Answer: (b)

Detailed Solution:

www.industrial.embedded-computing.com

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 6
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

As the length of Z travel increases in a C frame configuration, the machine tool stiffness,

a) Increases
b) Decreases
c) Varies in a sinusoidal manner
d) Varies in parabolic manner

Correct Answer: (b)

Detailed Solution:
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QUESTION 2:

Stiffness of closed loop structure is more than open loop structure due to

a) Strong ridged structural loop

b) Long arm length
c) High strength per weight ratio of components
d) Higher perpendicularity of the machine axes

Correct Answer: (a)

Detailed Solution:
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QUESTION 3:

Among the following structural configurations, in which one the workpiece table is capable of
moving in one or more directions?

a) Gantry type

b) Bridge type

c) Bed type

d) Fixed bed-moving column type

Correct Answer: (c)

Detailed Solution:
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QUESTION 4:

Which one of the following is the most suitable structural configuration for a vertical machining
center?

a) b) c) d)

Correct Answer: (a)

Detailed Solution:
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QUESTION 5:

Which of the following is considered as best strategy in cost vs. performance analysis?

a) Staying in the stagnant edge

b) Halting the machining before reaching leading edge
c) Staying in the leading edge
d) Staying in the bleeding edge

Correct Answer: (c)

Detailed Solution:
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QUESTION 6:

Imperfect geometry and dimensions of the machine components will result in,

a) Kinematic error
b) Dynamic force variations
c) Resonance
d) Thermo-mechanical errors

Correct Answer: (a)

Detailed Solution:
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QUESTION 7:

Adopting thermally symmetric structures will result in,

a) Low tool offset errors

b) High damping capabilities
c) High thermal conductivity
d) High thermal deflections

Correct Answer: (a)

Detailed Solution:
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QUESTION 8:

Which one of the following is the error caused by aging of the machine tool structures?

a) Temperature error
b) Tool edge rounding
c) Workpiece fixture placement error
d) Drift

Correct Answer: (d)

Detailed Solution:
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QUESTION 9:

Displacement error along the Y direction while moving in X direction will result in,

a) Straightness error
b) Flatness error
c) Roll error
d) Both straightness error and flatness error

Correct Answer: (a)

Detailed Solution:
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QUESTION 10:

Stick/slip behavior is the result of

a) Thermal deformations
b) Surface porosity
c) Hydrophobicity
d) Friction at contact surfaces

Correct Answer: (d)

Detailed Solution:

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 7
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Which of the following materials has the widest range of Young’s modulus and density?
a) Metal
b) Granite
c) Ceramic
d) Foam

Correct Answer: (d)

Detailed Solution:
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QUESTION 2:

Which of the following material is more commonly used as a packing material?

a) Polymer
b) Plastic
c) Foam
d) Elastomers

Correct Answer: (c)

Detailed Solution:
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QUESTION 3:

Which of the following material(s) is/are most widely used for construction of machine tool and
slideways?
a) Granite
b) Cast steel
c) Cast iron and aluminium
d) Granite and Cast iron

Correct Answer: (d)

Detailed Solution:
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QUESTION 4:

What are the constituents of granite which is used as a construction material for machine tool?
a) Mica, quartz, and sandstone
b) Sandstone, feldspar, and mica
c) Feldspar, quartz, and sandstone
d) Quartz, mica, and feldspar

Correct Answer: (d)

Detailed Solution:
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QUESTION 5:

What is the purpose of not choosing steel and granite combination for constructing machine tool?
a) It improves damping vibration capacity
b) It increase wear resistance
c) It presents the problem of stresses and bending in the interfaces
d) It provides excellent endurance life

Correct Answer: (c)

Detailed Solution:
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QUESTION 6:

According to the definition of basic static load rating

a) The total permanent deformation of the rolling element is less than 100 times the diameter of the
rolling element
b) The total permanent deformation of the rolling element is less than 1000 times the diameter of
the rolling element
c) The total permanent deformation of the rolling element is less than 10 times the diameter of the
rolling element
d) The total permanent deformation of the rolling element is less than 10000 times the diameter of
the rolling element

Correct Answer: (d)

Detailed Solution:
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QUESTION 7:

Assumption in the definition of basic static load rating __

a) Load is constant in magnitude but varying in direction
b) Load is constant in direction but varying in magnitude
c) Load is constant in direction and magnitude
d) Load is varying in direction and magnitude

Correct Answer: (c)

Detailed Solution:
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QUESTION 8:

According to the definition of basic dynamic load rating

a) A bearing can carry 1000000 revolutions with 99% reliability
b) A bearing can carry 100000 revolutions with 99% reliability
c) A bearing can carry 1000000 revolutions with 95% reliability
d) A bearing can carry 1000000 revolutions with 90% reliability

Correct Answer: (d)

Detailed Solution:

A Basic Dynamic Load Rating is a theoretical, statistically based value of load that a bearing can
carry for 1000000 revolutions with 90% reliability.
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QUESTION 9:

Backlash in the machine parts affects

a) Accuracy in the motion
b) Precision of the motion
c) Force applied by the tool
d) All of the above
e) only (a) and (c)
f) only (b) and (c)

Correct Answer: (d)

Detailed Solution:
Backlash present in the machine parts affects accuracy, precision, and force.
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QUESTION 10:

Geometric error in X direction while traveling in Z direction can be represented as

a) EXZZ
b) EZX
c) EZY
d) EXZ

Correct Answer: (d)

Detailed Solution:

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 9
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

In a 4-track encoder, what is/are the number of bit/s?

a) 1 Bit
b) 2 Bits
c) 3 Bits
d) 4 Bits

Correct Answer: (d)

Detailed Solution:
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QUESTION 2:

What is/are the possible cause of error/s in the calculation of actual position in rotary encoder?
a) Due to backlash of ball screw
b) Due to thermal changes of ball screw
c) Due to wear of ball screw
d) All of the above
e) only (a) and (b)
f) only (a) and (c)

Correct Answer: (d)

Detailed Solution:
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QUESTION 3:

In micromachining, high spindle speed is required due to?

a) Small diameter of the tool
b) Small length of the tool
c) High stiffness of the tool
d) Low stiffness of the tool

Correct Answer: (a)

Detailed Solution:
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QUESTION 4:

In micromachining, for obtaining high spindle speed one must choose?

a) Belt driven spindle
b) Integral motor-spindle
c) Single motor spindle
d) Both (a) and (b)

Correct Answer: (b)

Detailed Solution:
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QUESTION 5:

Which of the following component is not incorporated in the spindle shaft of the belt driven
spindle?
a) Draw bar
b) Tool release system
c) Tool taper and tooling system
d) Cooling system arrangement

Correct Answer: (d)

Detailed Solution:
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QUESTION 6:

Which is required in angular contact ball bearing for greater axial load carrying capacity?
a) High lubrication
b) High contact angle
c) High rotational speed
d) High run out

Correct Answer: (b)

Detailed Solution:
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QUESTION 7:

Why controlled radial play is necessary between balls and rings?

a) To get free movement of balls
b) To avoid heating up
c) To increase bearing life
d) All of the above
e) only (b) and (c)
f) only (a) and (b)

Correct Answer: (d)

Detailed Solution:
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QUESTION 8:

What is/are the different method/s of bearing preload?

a) Spring preload
b) Solid preload
c) Damper preload
d) All of the above
e) Both (a) and (b)
f) Both (b) and (c)

Correct Answer: (e)

Detailed Solution:
It is spring and solid bearing preload.
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QUESTION 9:

Which of the following statement is true in context of heavy preloading?

a) It allows less speed and high stiffness
b) It allows high stiffness and high speed
c) It allows less speed and less stiffness
d) It allows high speed and less stiffness

Correct Answer: (a)

Detailed Solution:
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QUESTION 10:

Insufficient preloading the bearing results in

a) Increased vibration and fretting of the raceways
b) Increased stress, torque, heat, and resolution
c) Decreased vibration, torque, and heat
d) Increased stress, surface finish, and fatigue

Correct Answer: (a)

Detailed Solution:

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 10
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

In hybrid ceramic bearing, inner and outer races are made up of __

a) Ceramic
b) Steel
c) Tungsten carbide
d) Aluminum

Correct Answer: (b)

Detailed Solution:
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QUESTION 2:

Which of the following statement/s is/are true in the context of bearings?

a) Aerostatic bearing operates at a lower speed as compared to the hybrid ceramic bearing
b) Hybrid ceramic bearing operates at a lower speed as compared to the aerostatic bearing
c) Torque required by hybrid ceramic bearing is less as compared to aerostatic bearing
d) Both (a) and (c)
e) Both (b) and (c)

Correct Answer: (b)

Detailed Solution:
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QUESTION 3:

What is the cause of aerostatic spindle warpage?

a) It is due to differential expansion at certain locations on the spindle due to hot air impinging
b) It is due to differential contraction at certain locations on the spindle due to cold air impinging
c) It is due to differential expansion at certain locations on the spindle due to mist air impinging
d) It is due to differential contraction at certain locations on the spindle due to cold water impinging

Correct Answer: (b)

Detailed Solution:
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QUESTION 4:

In high speed micromachining, bell mouthing is a problem which appears due to the
a) Expansion of spindle shaft
b) Slippage of tool holder
c) Vibration of the machine tool
d) Bending of the micro tool

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 48, Time: 8:00)

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QUESTION 5:

Which tool retention system is preferable for high speed spindle used in high precision machining
centers?

a) BT
b) CAT
c) ISO
d) HSK

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 48, Time: 11:00)

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QUESTION 6:

The required properties of a micro cutting tool is/are

a) High coefficient of friction
b) More number of cutting edges
c) Desired flank geometry
d) Both (a) and (b)
e) Both (a) and (c)

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 49, Time: 13:33)

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QUESTION 7:

What is the full form of WEDG (a well-known micro tool fabrication process)?
a) Wear electric diamond grinding
b) Water electric discharge grinding
c) Wire electric discharge grinding
d) Wire electric diamond grinding

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 50, Time: 3:03)

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QUESTION 8:

Removal of the material and re-sharpening of the grinding wheel both occurs simultaneously in
a) Micro-grinding
b) Wire electric discharge grinding
c) Electrolytic in-process dressing (ELID)
d) Piezoelectric or Nano-grinding

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 51, Time: 2:49)

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QUESTION 9:

The micro-tool with dull cutting edges likely to be broken because

a) Stress increases beyond the permissible limit.

b) Material cannot be removed.
c) The tool becomes mechanically weak.
d) None of the above

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 51, Time: 11:51)

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QUESTION 10:

In electro discharge machining (EDM), the material is removed by

a) Formation of chips
b) Melting
c) Melting and vaporizing
d) All of the above

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 52, Time: 3:25)

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 11
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Bending of the micro tools becomes prominent when

a) Both spindle speed and feed rate are high

b) Both spindle speed and feed rate are low

c) Spindle speed low but feed rate high

d) Spindle speed high but feed rate low

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 53, Time: 3:03)

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QUESTION 2:

Which one is not the key issue for the breakage of micro tools?

a) Higher cutting forces relative to size

b) Chip clogging
c) Formation of built-up edge (BUE)
d) High temperature

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 53, Time: 3:25)

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QUESTION 3:

What are the limitations to make a small–scale micro machine tools

a) Lack of rigidity
b) Base vibration
c) Machining difficulties
d) Both (a) and (b)
e) Both (a) and (c)
f) Both (b) and (c)

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 54, Time: 5:01)

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QUESTION 4:

Advantages expected from micro factories are

a) Capital investment is reduced

b) High speed machining is possible
c) Proper utilization of the space
d) Both (a) and (b)
e) Both (a) and (c)
f) Both (b) and (c)

Correct Answer: (e)

Detailed Solution:

(Refer: Lecture 54, Time: 7:44)

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QUESTION 5:

Advantages expected from micro factories in terms of technical aspect is/are

a) Freedom of configuration
b) Low resonant frequency
c) Shortened ramp-up
d) Only (a) and (b)
e) Only (a) and (c)

Correct Answer: (e)

Detailed Solution:

(Refer: Lecture 55, Time: 4:07)

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QUESTION 6:

The advantages of micro factories in terms of environmental aspects is /are

a) No coolant or lubrication required

b) Only a few operators required
c) Easy control of waste and pollution
d) All of the above

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 55, Time: 6:41)

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QUESTION 7:

The suitable tool material for ultra-precision machining is

a) HSS
b) Coated tungsten carbide
c) Natural diamond
d) CBN

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 56, Time: 6:21)

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QUESTION 8:

The most useful process for the fabrication of astronomical telescope mirrors is
a) Diamond turning
b) CNC machining
c) Grinding
d) Honing

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 56, Time: 8:09)

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QUESTION 9:

In X-Z axis diamond turning machine, the tool slide along

a) X axis

b) Y axis

c) Z axis

d) None of the above

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 57, Time: 2:00)

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QUESTION 10:

The preferable configuration to generate concave surface in DTM is

a) X-Z configuration

b) R- ϴ configuration

c) X-T configuration

d) All of the above

Correct Answer: (b)

Detailed Solution:

(Refer: Lecture 57, Time: 8:15)

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 12
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

The material removal rate (MRR in mm3/min) of turning process can be expressed as
a) Depth of cut × feed × cutting velocity
b) Depth of cut × feed
c) Feed × cutting velocity
d) None of the above

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 58, Time: 2:08)

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QUESTION 2:

Important parameters for average material removal rate of lapping process (i.e., soft –loop finishing
technique) are
a) Depth of cut, feed, cutting velocity
b) Depth of cut and feed
c) Feed and cutting velocity
d) Pressure and velocity

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 58, Time: 4:02)

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QUESTION 3:

When the uncut chip thickness is more than 10 µm then

a) Grain boundaries become the origin of breakage
b) Dislocation become origin of breakage
c) Point defects spaced between 1-100 nm become the origin of breakage
d) None of the above

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 58, Time: 7:41)

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QUESTION 4:

In diamond turning, the cutting tool with smaller nose radius is suitable
a) To make smaller features
b) To machine fragile job
c) To make external features
d) Both (a) and (b)
e) Both (a) and (c)

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 59, Time: 1:04)

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QUESTION 5:

Peak-to-valley height (h) of the diamond turned surface can be calculated as (where f is feed per
revolution and R is nose radius)
a) f2/8R
b) f2/2R
c) f2/6R
d) f2/R

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 59, Time: 2:03)

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QUESTION 6:

Basic compositions of sensing system are

a) Sensor, Transform or conversion, Signal processing, and Decision making

b) Sensor, Signal processing, Machine, and Decision making

c) Machine, Transform or conversion, and Signal processing

d) Machine, Operator, Decision making and Sensor

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 60, Time: 11:41)

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QUESTION 7:

Real time monitoring of the machining operation falls under

a) Continuous measurement system
b) Intermittent measurement system
c) Multiple measurement system
d) Coherence measurement system

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 61, Time: 1:25)

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QUESTION 8:

Cutting forces are usually measured by

a) Pyrometer
b) Dynamometer
c) High speed camera
d) Accelerometer

Correct Answer: (b)

Detailed Solution:

(Refer: Lecture 61, Time: 11:20)

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QUESTION 9:

Acoustic emission can monitor the

a) Deformation at submicron scale with high level of precision

b) Deformation at millimeter scale with high level of precision

c) Deformation at submicron scale with low level of precision

d) Deformation at millimeter scale with low level of precision

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 62, Time: 2:37)

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QUESTION 10:

Sources of acoustic emission (AE) in machining is/are

a) Elastic recovery of material
b) Material softening
c) Both (a) and (b)
d) Neither (a) nor (b)

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 62, Time: 3:46)

***********END***********