Mechanical Engineering MCQs – Chemical Processes ( Advanced Machining Processes ) MCQs
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Mechanical Engineering MCQs – Chemical Processes ( Advanced Machining Processes ) MCQs
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Photo Chemical Millling-Introduction
1. In advanced machining process, what is the full form of PCM?
a) Photochemical manufacturing
b) Photochemical machining
c) Photo crystalline manufacturing
d) Photo crystalline machining
Answer: b
Explanation: Full form of PCM in advanced machining processes is Photochemical milling.
2. In this method, which of the following techniques are used to apply the maskant on the machining surface?
a) Photographic techniques
b) Cut and peel masking
c) Silkscreen resist technique
d) None of the mentioned
Answer: a
Explanation: Maskant is applied on the machining surface using photographic techniques in PCM.
3. What is the similarity between normal Chemical milling process and Photo chemical milling?
a) Both use chemicals
b) Maskant application method
c) None of the mentioned
d) All of the mentioned
Answer: a
Explanation: Both method are similar in one property i.e.., they both use chemicals.
4. In some cases, Photochemical milling can also be called as ______________
a) Photo chemical blasting
b) Photo chemical blanking
c) Photo chemical drilling
d) Photo chemical erosion
Answer: b
Explanation: In some cases flat, thin gauge complex parts can be machined, this process is known as Photochemical Blanking (PCB).
5. Photo chemical blanking can be used to machine the parts to high precision, up to which of the following thickness values?
a) 0.001 – 0.007 mm
b) 0.007 – 0.012 mm
c) 0.013 – 1.503 mm
d) 1.612 – 2.125 mm
Answer: c
Explanation: PCB can be used to machine parts of thickness 0.013 – 1.50 mm to high precision.
6. State whether the following statement is true or false regarding Photochemical milling.
“Unlike that of CHM, PCM can also be used to create parts.”
a) True
b) False
Answer: a
Explanation: In CHM original parts manufactured in other processes are machined. Unlike that case, in PCM parts can be created from thin sheets using maskants.
7. In case of photochemical milling that use using lettering and graphics for surface etching, what will be the depth of surface etched?
a) Very deep
b) Up to certain depth
c) Half-way
d) None of the mentioned
Answer: b
Explanation: Sometimes photochemical machining is used to surface-etch components with lettering or graphics, in which etchant works to only a certain depth.
8. When was the process, Photochemical milling is introduced to the machining environment?
a) 1920s
b) 1930s
c) 1950s
d) 1960s
Answer: d
Explanation: PCM was introduced to the machining industry in 1960s, as an offshoot of PCBs.
9. State whether the following statement is true or false regarding PCM.
“In PCM, etching depth does not depend on the time, a component is immersed in the chemical solution.”
a) True
b) False
Answer: b
Explanation: As in case of CHM, depth of etch in PCM depend upon the time of part immersed in chemical solution.
10. Which of the following processes does not come under Chemical machining processes?
a) Chemical milling
b) Photo forming
c) Photo chemical filling
d) Photo chemical blanking
Answer: b
Explanation: Photo forming is a process of electro plating metals over the mandrels which does not use chemical for material removal.
PCM-Process Description
1. Which of the following is the first step in Photo chemical milling process?
a) Generation of photographic film
b) Etching the part
c) Removal of etchant
d) Photo resist stripping
Answer: a
Explanation: Generation of photographic film using CAD drawings is the first step in PCM.
2. What is the other name for photographic film generated in Photochemical milling?
a) Photo mask
b) Photo tool
c) Photo cover
d) Photo plate
Answer: b
Explanation: The photographic film generated using CAD drawings, which is also called as Photo tool.
3. What is the next step after generation of Photo-tool?
a) Chemical cleaning
b) Coating of photo tool
c) None of the mentioned
d) All of the mentioned
Answer: d
Explanation: After generation of photo-tool, it is applied to the chemically cleaned work surface.
4. What is the use of photo tool in Photochemical milling process?
a) Cleaning of work piece
b) Protection of surface against etching
c) Etching of part surface
d) None of the mentioned
Answer: b
Explanation: In PCM, photo tool is applied as coating which act as stencil resist that protect the surface from etching.
5. Where are the photo tools applied on the surface of the work piece material?
a) On the top
b) On the bottom
c) All of the mentioned
d) None of the mentioned
Answer: c
Explanation: Photo tools are applied in pairs- one on the top and one on the bottom like sandwiching work piece between photo layers.
6. The photo tool is exposed to which light source, in order to form a replica of image of the required geometry?
a) Infrared sources
b) Ultraviolet source
c) Normal light source
d) None of the mentioned
Answer: b
Explanation: Ultraviolet light sources are used to transfer the image of the required geometry on to the resist, precisely.
7. Which can be used as solutions which develop the photo resists in PCM?
a) Water
b) Alkaline solution
c) Hydrocarbons
d) All of the mentioned
Answer: d
Explanation: In PCM, the solutions mentioned above can be used to develop the photoresist films on the surfaces.
8. What is the next step after creating the photo tool and adhering it to work piece using UV light source?
a) Finishing
b) Etching
c) Rinsing and drying
d) None of the mentioned
Answer: b
Explanation: After the image is adhered to work piece, etching is done.
9. The right choice of etchant depend on, which of the following factors?
a) Rate of material removal
b) Etching depth
c) Cost and quality
d) All of the mentioned
Answer: d
Explanation: Etchant selection depends on cost, quality, etch depth and MRR rate.
10. After etching is done, what is the next step in Photochemical milling process?
a) Finishing
b) Rinsing and drying
c) Removal of protective layer
d) None of the mentioned
Answer: b
Explanation: After etching is done in PCM, the parts are rinsed and dried.
11. How are the protective layer coatings on the parts are removed?
a) Use of chemicals
b) Mechanical techniques with chemicals
c) None of the mentioned
d) All of the mentioned
Answer: d
Explanation: The protective layers are removed by the use of chemicals and by using mechanical techniques with chemicals.
PCM-Applications and Advantages
1. Which of the following are the metals that can be machined using Photo chemical milling?
a) Aluminium
b) Copper
c) Nickel
d) All of the mentioned
Answer: d
Explanation: Copper, aluminium, zinc, steel, molybdenum, zirconium, titanium are some of the metals that can be machined using PCM.
2. Which of the following non-metallic materials that can be machined using PCM?
a) Glass
b) Ceramics
c) Some plastics
d) All of the mentioned
Answer: d
Explanation: The non-metallic materials mentioned above, can be machined using PCM.
3. Which of the following materials are excellent for Photochemical milling?
a) Brittle materials
b) Ductile materials
c) Elastic materials
d) None of the mentioned
Answer: a
Explanation: Brittle materials are excellent candidates for PCM, since they tend to break easily using traditional machining processes.
4. State whether the following statement is true or false about applications of PCM.
“Using PCM, very high tempered materials are machined easily.”
a) True
b) False
Answer: a
Explanation: PCM can be favourable for very high tempered and brittle materials unlike that of traditional machining, where they tend to break easily.
5. Which of the following are the typical applications of Photo chemical milling?
a) Production of signs
b) Production of labels
c) Fabrication of boxes and enclosures
d) All of the mentioned
Answer: d
Explanation: Using PCM, the above mentioned applications can be fulfilled.
6. What is the value of thickness of work pieces to be used in PCM?
a) 0.001 – 0.003 mm
b) 0.013 – 1.50 mm
c) 1.50 – 2.35 mm
d) 2.50 – 3.33 mm
Answer: b
Explanation: The thickness value of work pieces in PCM range between 0.013 – 1.50 mm.
7. What type of work pieces must be used in Photochemical milling process?
a) Bent surfaces
b) Rolled surfaces
c) Flat surfaces
d) None of the mentioned
Answer: c
Explanation: The work pieces must be flat in order to carry on the PCM process.
8. Which of the following industries use PCM for different applications?
a) Electronic
b) Automotive
c) Telecommunication
d) All of the mentioned
Answer: d
Explanation: PCM has its applications in the industries such as electronics, automotive, telecommunication, computer, medical, aerospace and other industries.
9. Which of the following are the components that can be machined using PCM?
a) Filters and screens
b) Lead frames
c) Connectors and probes
d) All of the mentioned
Answer: d
Explanation: Typical components such as gaskets, lead frames, contacts, connectors, probes, filters and screens can be machined using PCM.
10. What is the cost per unit for low production volumes of complex designs using PCM?
a) Low
b) Medium
c) High
d) None of the mentioned
Answer: a
Explanation: Relatively low cost per unit is required in PCM, since tooling is inexpensive compared to that of traditional practices.
11. State whether the following statement is true or false regarding advantages of PCM.
“In PCM, lead times are large, when compared to that required for hard tooling using traditional means.”
a) True
b) False
Answer: b
Explanation: Lead times are small when compared to that required by processes that require hard tooling.
12. Which of the following factors can change the parameters of etch such as depth, size of hole etc.?
a) Time of etch
b) Type of etchant
c) All of the mentioned
d) None of the mentioned
Answer: c
Explanation: Type of etchant used and time for etching can change the features such as hole size and depth of etch.
13. How much amount of burr is produced, when components are machined using PCM?
a) Small
b) Medium
c) Large
d) No burr
Answer: d
Explanation: Photochemical milling is a burr-free process i.e.., burr is not produced in this process.
14. Which of the following properties of materials are changed by using Photochemical milling?
a) Hardness of material
b) Ductility of material
c) Grain structure
d) None of the mentioned
Answer: d
Explanation: In PCM, material properties such as hardness, ductility and grain structure are not changed.
15. State whether the following statement is true or false regarding advantages of PCM.
“Patterns can be reproduced easily.”
a) True
b) False
Answer: a
Explanation: Patterns can be reproduced easily because tooling is made by photographic techniques.
Electro Polishing-Introduction
1. In advanced machining processes, what is the full form of EP?
a) Electro plating
b) Electro polishing
c) Electron pocketing
d) Electrical punching
Answer: b
Explanation: Full form of EP is Electro-polishing in advanced machining processes.
2. When was the process Electro polishing introduced to the advanced machining processes?
a) 1918
b) 1922
c) 1935
d) 1943
Answer: c
Explanation: Electropolishing was introduced to world in the year 1935, when Cu and Zn were successfully electropolished by Germans.
3. How is the material removed in Electropolishing process?
a) Anodic dissolution
b) Cathodic dissolution
c) Chemical corrosion
d) Mechanical erosion
Answer: a
Explanation: Material in Electropolishing is removed by anodic dissolution process.
4. State whether the following statement is true or false regarding EP process.
“Electropolishing is same as electro plating.”
a) True
b) False
Answer: b
Explanation: Electropolishing is the opposite of electroplating.
5. In the following terminals, part to be finished acts as which terminal in EP process?
a) Anode
b) Cathode
c) Neutral
d) None of the mentioned
Answer: a
Explanation: As this process is opposite to that of Electro plating, part to be finished is the anode in EP.
6. Which of the following come under the components of EP process?
a) Electrolyte solution
b) Dc power supply
c) Work piece
d) All of the mentioned
Answer: d
Explanation: The EP process components include DC power supply, electrolyte, electrically charged terminals, of which, one of them is work piece.
7. Electrolytic solution is a mixture of which of the following?
a) Insoluble salts
b) Several acids
c) All of them mentioned
d) None of the mentioned
Answer: c
Explanation: Electrolytic solution is a mixture of several acids and insoluble salts.
8. What amount of current density can be used for Electropolishing to take place?
a) Very low
b) Low
c) Optimum
d) Very high
Answer: b
Explanation: Limiting amount of current should be used in EP process for anodic dissolution.
9. Which of the following takes place if the current density used is relatively high?
a) Smoothing
b) Finishing
c) Oxygen evolution
d) All of the mentioned
Answer: c
Explanation: If the current level increases beyond the limiting value, pitting takes place due to gas evolution.
10. More anodic dissolution takes place at which part of the surface of the work piece?
a) Peaks
b) Valleys
c) Troughs
d) None of the mentioned
Answer: a
Explanation: Anodic dissolution is high at peaks when compared to valleys on the surface of the work pieces.
11. State whether the following statement is true or false about EP process.
“In EP, produced surface possess true crystalline structure without distortion.”
a) True
b) False
Answer: a
Explanation: In Electropolishing, the produced surface possess true crystalline structure without distortion, unlike that of cold working as in mechanical finishing.
12. Surfaces produced in Electropolishing process possess which of the qualities?
a) Bright
b) Clean
c) Microscopically smooth
d) All of the mentioned
Answer: d
Explanation: Surfaces produced in EP becomes clean, bright and microscopically smooth.
13. How much amount of properties of bulk material, are possessed by the finished part in EP?
a) Negligible amount
b) Only some properties
c) All properties
d) None of the mentioned
Answer: c
Explanation: The part machined using EP process, possess true properties of the bulk material.
14. State whether the following statement is true or false regarding EP.
“Fine direction lines are left in EP, like that of abrasive polishing.”
a) True
b) False
Answer: b
Explanation: Unlike that of abrasive polishing, fine direction lines are not produced.
EP-Process Parameters
1. Of the following material removal mechanisms, material is removed by which one in EP?
a) Electrode dissolution
b) Corrosion
c) Abrasion
d) Erosion
Answer: a
Explanation: Anodic dissolution takes place in Electropolishing process.
2. Which of the following come under the process parameters of the Electropolishing?
a) Work piece material and condition
b) Current density
c) Applied voltage
d) All of the mentioned
Answer: d
Explanation: The process parameters of Electropolishing include current density, applied voltage, acid type, temperature original surface roughness, work piece condition and material.
3. Current density of the EP process generally varies between which of the following values?
a) 0.0001 – 0.001 A/cm2
b) 0.005 – 1.8 A/cm2
c) 1.9 – 2.532 A/cm2
d) 3.523 – 4.23 A/cm2
Answer: b
Explanation: Generally current density value used in EP process vary between 0.005 – 1.8 A/cm2.
4. Which of the following are the work piece materials that can be machined using Electropolishing?
a) Carbon steel
b) Alpha brass
c) Phosphor bronze
d) All of the mentioned
Answer: d
Explanation: Different work piece materials that can be machined using EP are carbon steels, stainless steels, copper, alpha brass, nickel, phosphor bronze, aluminium, magnesium etc.
5. Which of the following electrolyte, can be used commonly for stainless steel, Cu, Ni and Mg?
a) HCLO4
b) H2PO4
c) H2SO4
d) HNO3
Answer: b
Explanation: H2PO4 is a common electrolyte used in the machining of Cu, Ni, Mg.
6. What is the electrolytic solution’s temperature when stainless steel is machined?
a) 50o C
b) 80o C
c) 120o C
d) 150o C
Answer: b
Explanation: Temperature of electrolytic solution used for machining stainless steel is 80o C.
7. State whether the following statement is true or false regarding process parameters of EP.
“In EP, process parameters have a direct impact on surface quality and productivity of process.”
a) True
b) False
Answer: a
Explanation: In Electropolishing, parameters have a direct impact on quality of surface and productivity.
8. For machining of Cu material which of the following can be used as electrolytes?
a) H2PO4
b) H2PO4 and Na2CrO4
c) HCLO4
d) HNO3
Answer: a
Explanation: For Cu material electrolyte used in EP process is H2PO4.
9. In the following types of voltage, which one best suites EP process?
a) Randomly Fluctuating
b) Constant
c) Periodically fluctuating
d) None of the mentioned
Answer: b
Explanation: For the machining to take place in Electropolishing process, voltage should be correct and constant.
10. State whether the following statement is true or false regarding process parameters of EP.
“In EP, high current densities are used for anodic dissolution.”
a) True
b) False
Answer: b
Explanation: In Electropolishing, limited current densities are used for anodic dissolution.
EP-Applications and Limitations
1. For economical and high quality Electropolishing, which of the following materials are used?
a) Cold rolled metals
b) Hot flat metals
c) Hot plastics
d) All of the mentioned
Answer: a
Explanation: Cold rolled metals are the most important materials for economical and high quality polishing.
2. State whether the following statement is true or false about applications of EP.
“In EP, cast items do not maintain the texture of sand mold.”
a) True
b) False
Answer: b
Explanation: Cast items usually maintain the texture of sand mold since they have coarse grains and include alloying elements.
3. Which of the following cannot be removed by using Electropolishing process?
a) Scales
b) Distortion
c) Coarse texture
d) Burrs
Answer: c
Explanation: Coarse texture cannot be removed using Electropolishing as they produce rough surfaces.
4. Electropolishing prepares surfaces for which of the following processes?
a) Electron Beam machining
b) Electro plating
c) Laser beam machining
d) Magnetic Abrasive machining
Answer: b
Explanation: EP prepares surfaces for electroplating, which creates an opportunity for best adherence.
5. For which of the following components, polishing can be done using EP?
a) Electrical conduits
b) Outlet boxes
c) Medical equipment
d) All of the mentioned
Answer: d
Explanation: Polishing light fixtures of electrical conduits, outlet boxes, and medical, surgical, and food processing equipment.
6. State whether the following statement is true or false regarding the applications of EP.
“Using Electropolishing, deburring and breaking sharp edges can be done.”
a) True
b) False
Answer: a
Explanation: Deburring and breaking sharp edges obtained from hand filing, grinding and honing of tools.
7. Electropolishing removes scales and distortions that are produces by which of the processes below?
a) Annealing
b) Nitriding
c) Carburizing
d) All of the mentioned
Answer: d
Explanation: Scales and distortions produced by annealing, carburizing, nitriding, welding and soldering can be removed using EP.
8. State whether the following statement is true or false about applications of EP.
“In EP, removal of hardness and stressed surface layers, reduces life of parts.”
a) True
b) False
Answer: b
Explanation: Removal of hardness and stressed surface layers improves the surface life of part.
9. Polishing of how many parts can be done using Electropolishing?
a) One part
b) Two parts
c) Multiple parts
d) None of the mentioned
Answer: c
Explanation: Multiple parts can be polished simultaneously using EP, depending upon the size of parts.
10. Electropolishing cannot cover up which type of defects?
a) Burrs on surfaces
b) Scales and distortions
c) Non-metallic inclusions
d) Metallographic examination
Answer: c
Explanation: Seams and non-metallic inclusions are some defects which cannot be covered up using EP.
11. Which of the following is a limitation of EP process?
a) Rough scratches removal
b) Scales removal
c) Distortions removal
d) Burr removal
Answer: a
Explanation: In EP, rough scratches cannot be removed even by considerable amount of process.
12. Metals containing which of the following chemicals will be troublesome in EP process?
a) Silicon
b) Lead
c) Sulphur
d) All of them mentioned
Answer: d
Explanation: All the elements mentioned above, if present in metals, will be troublesome in EP process.
13. State whether the following statement is true or false regarding the limitations of EP.
“In EP, base metal condition does not affect the process.”
a) True
b) False
Answer: b
Explanation: Base metal condition affects the process of EP.
14. Which of the following defects lead to poor electropolishing of the surfaces?
a) Improper annealing
b) Non-metallic inclusions
c) Over pickling
d) All of the mentioned
Answer: d
Explanation: Non-metallic inclusions, over pickling, large grain size, direction roll marks, improper cold reduction leads to poor electro polishing.
15. Electropolishing is more suited for, removal of which of the following defects?
a) Small scratches
b) Imperfections
c) Smoothing
d) All of the mentioned
Answer: d
Explanation: Small scratches and imperfections can be easily removed when compared to that of rough scratches.