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Question Paper Code : AME11T29

VARDHAMAN COLLEGE OF ENGINEERING(AUTONOMOUS)

Affiliated to JNTUH, HyderabadFour Year B. Tech VI Semester Tutorial Question Bank 2013 - 14

(Regulations: VCE-R11)Unconventional machining process

(Mechanical Engineering Department)PART-A (2 Mark Questions)

Unit-I1. Enlist the requirements that demands the use of advanced machining process2. Non-conventional manufacturing processes may be classified on the basis of type of energy used as3. Differentiate between traditional and nontraditional machining process4. What is the need for using nontraditional machining 5. What are industrial needs for unconventional machining processes?6. Why is unconventional mechanical process not popular7. List out the different types of thermoelectric advanced machining process8. Which type of machining process is applicable to machine Biodegradable Plastics?9. How the energy will supplied In thermoelectric marching process?

10. Name the important factors that should consider during the selection of an unconventional machining process on for a given job.

Unit-II1. write down the energy transfer media, energy source and mechanism of metal removal for water jet

machining process2. what are the variables that affects the cutting phenomena in abrasive jet machining 3. what are the major elements of ultrasonic machining equipment4. what are the characteristics of a good suspension media of the USM process5. mention the application of catcher in water jet machining

6. give the range of frequency required for ultrasonic machining 7. define the functions of transducers in ultrasonic machining 8. why is abrasive jet machining not recommended to machine ductile materials 9. how do you minimize pulsation in water jet machining

10. list out the applications of Abrasive water jet machining processUnit-III

1. Describe the properties of electrolyte used in ECM process?2. Why is the surface finish obtained in CHM of alloys poor?3. Mention the specific applications of electro chemical grinding.4. Distinguish between electrical machining and electro plating process? 5. What are the various process parameters which effective of electrochemical grinding depend upon?6. complete the following chemical reactions in ECM

(a)2Fe+4H2O+O2 (for low valency of dissolution)(b) 2Fe+4H2O+O2 (for high valency of dissolution)

7. Mention the specific applications for electro chemical machining process8. Describe the theory of Electrochemical machining process9. Mention different types of electrolyte used in Electrochemical machining process

10. Describe the advantages of Electrochemical machining processUnit-IV

1. what are the ways of gap flushing used in EDM2. what are the categories in to which the variety of power supply circuits in EDM process can be

classified3. what are the functions of adaptive control used for EDM

4. what do you mean by recast layer with reference to the EDM5. name the wire materials which are used in wire cut EDM 6. What is dielectric system7. What is the influence of dielectric contamination on the EDM?8. Mention the factors influencing the choice of electrode materials in EDM9. List out any two advantages of Electric Discharge Marching process

10. Mention the specific application of Electric Discharge Marching processUnit-V

1. What do you understand by fourth state of matter?2. How is the work table protected from getting damaged by EBM while machining the work piece?3. what are the advantages of Electron beam machining process?4. What is the function of water muffler in PAM?5. List out any two application of Electron beam machining process6. What is principle of plasma arc machining? What are the two stages in which the process of material

removal is affected?7. In electron beam machining, why is a high vacuum created in apparatus ?8. List out any two application for plasma arc welding process?9. Can you machine electrically non-conducting materials using EBM process?

10. What is the function of electron beam gun?PART-B (5 Mark Questions)

Unit-I1. Classify modern marching process on the basis of the types of energy employed also, state the

mechanism of material removal, transfer media, and energy sources used2. What do you understand by the word “unconventional”, in unconventional machining process? Is it

justified to use this word in the context of the utilization of these of these processes on the shop floor?

3. how the developments in the area of materials are partly responsible for evolution of advanced machining process

4. Explain the factors that should be considered during the selection of an appropriate unconventional machining process for a given a job?

5. Compare and contrast the various unconventional machining process on the basis of the type of energy employed, material removal rate, transfer media and economical aspects

6. How will you analyze the applicability of different processes to different types of materials, namely metals, alloys and nonmetals? presentation in the form of table is preferred

7. Explain the some important characteristics of advanced machining process8. Describe the different types of hybrid process and electrical discharge abrasive grinding is called as

hybrid process give suitable reason9. Explain the basis which modern machining are classified. Why the unconventional machining process

to completely taking over the conventional machining process?10. name the important factors that should be considered during selection of unconventional machining

process for given job? Unit-II

1. What are the actions do the ultrasonic vibration imparted to the fluid medium surrounding the tools have? What are the process criteria of USM? What are the various process parameters that govern the process criteria?

2. Draw the schematic layout of abrasive jet machine and explain its operational characteristics. What are the methods adopted to have an effective control over the mass flow rate of abrasive?

3. Make comparison between ultrasonic machining and conventional grinding process4. explain the working principle of Abrasive Jet machining mention some of the specific applications of

AJM5. Discuss in details about the AJM process variables that influence the rate of material removal and

accuracy in machining?6. Derive the explain for Material removal rate in case grain throwing and grain hammering

mechanism 7. Briefly discuss about the mechanism involved in material removal rate in USM8. write the brief note on the special feature of the equipment used in water jet machining process

with neat sketch9. Explain the working principle of abrasive water jet machining process and describe the advantages of

WJM 10. Discuss in detail about the methods of generating the ultrasonic, characteristics of the various types

of tool holder and tool feed mechanism in USMUnit-III

1. (a) describe the chemistry involved in electro chemical machining process(b)discuss about the economics of electro chemical machining process

2. Briefly discuss about the effect of high temperature and pressure of electrolyte on the ECM process?3. Explain the working principle, equipments, chemistry of process of Electro chemical machining

process4. Explain the principles, equipment, accuracy and surface finish, process capabilities electrochemical

grinding process5. What are three methods of metal removal by electrolytic action in combination with ribbing of

workpiece in ECG process?6. Explain with diagram .what are the conditions to be satisfied to ensure high effective of ECG

methods of machining?7. Discuss the effect of high temperature and pressure of electrolyte on ECM process.8. Briefly discuss about electro chemical deburring process9. Using Faraday’s laws of electrolysis derive and equation to compute maximum permissible feed rate.

10. calculate MRR when a current of 2000A is used . use the lowest valance dissolution in each caseUnit-IV

1. Explain the working principle, elements and characteristics of Electric discharge machining process with neat sketch?

2. Explain the following terms:(a) Duty factor (b) ignition delay(c) flash point(d) critical circuit

3. What are the functions of an ‘adaptive control system’ used for EDM?4. With help of neat sketch , explain the mechanism of materials removal rate in Electric Discharge

machining process?5. Find the condition for maximum power delivery to the discharging circuit in Electric Discharge

machining process?6. write short notes on the following :

(a) Re-solidification of molten metal in Electric Discharge machining process(b) Minimization of bowing of wire in wire EDM

7. Draw the scheme of electro-discharge wire cutting machine and explain its principle of operation. Also discuss the operating process parameters and their effects.

8. how will you carry out the analysis for optimization of metal removal rate in Electric Discharge machining process

9. what are the steps that are to be adopted in sequence while applying the linear programming technique to optimize the metal removal rate in EDM process

10. describe the advantages and disadvantages of Electric Discharge machining processUnit-V

1. What are unique characteristics a laser machining technique possesses that make it the only choice for the job.

2. What is meant by optical pumping? Briefly explain the “population inversion between energy levels” with respect to laser beam machining?

3. Derive an expression for dimensionless analysis to establish correlation between EBM parameters 4. Draw the schematic set up of plasma arc machine . indicate various parts5. Briefly explain the following with respect to chemical machining

(a) Characteristics of cut and peel maskants(b) Selection maskants

6. What is non-transferred and transferred mode of plasma arc? Explain the mechanism of material removal in PAM

7. What is laser ?explain how it is used to machine the material s?8. Discuss the factors that influence the quality of the cut in Plasma Arc machining 9. explain the principle and elements of EBM also how the work table is protected from f=getting

damaged by electron beam 10. Briefly explain the following with respect to chemical machining

(a) Advantages of photoresit maskants(b) Limitations of chemical maching