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DEPARTMENT OF MECHANICAL ENGINEERING

ME6004-UNCONVENTIONAL MACHINING PROCESS


UNIT-I INRODUCTION
PART-A
1. What are the industrial needs for unconventional machining AM-15 K1
processes? ND-16
MJ-16
2. Write down the energy transfer media, energy source and MJ-09 K1
mechanism of metal removed for the following process.
a. Water jet machining.
b. Electromagnetic grinding.
3. State the needs of non-traditional machining processes. AM-10 K2
4. List down various mechanical energy based unconventional AM-10 K3
machining processes.
5. Name the important factors that should be considered during AM-11 K2
the selection of an unconventional machining process for a ND-14
given job.
6. Classify modern machining processes on the basis of the AM-11 K3
types of energy employed. MJ-16
7. What is the necessity of unconventional (or) non-traditional MJ-12 K2
machining process?
8. Mention the thermal energy based unconventional machining MJ-12 K3
processes.
9. List the important characteristics of unconventional ND-14 K2
machining process
10. Write the importance of surface finishing in machining MJ-14 K2
operations.
11. Compare the conventional and unconventional machining ND-15 K3
process ND-16
12. Enlist the requirement that demand the use of advanced AM-17 K2
machining process.
13. Suggest the suitable unconventional machining process to cut AM-17 K4
a thin glass plate into 2 pieces.
14. Classify the different types of unconventional machining AM-18 K3
process based on mechanical energy.
15. What are the desirable properties of carrier gas in AJM? AM-18 K2
Part-B
1. For different non-conventional processes, present in the form MJ-09 K2
of a table, various process parameters recommended.(13)

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2. How will you analyse the applicability of different processes to MJ-09 K4
different types of materials, namely metals, alloys and non-
metals? Presentation in the form of a table is preferred.(13)

3. Classify unconventional machining processes based on basic AM-10 K2


mechanism involved in the process, sources of energy
required for material removed, and medium for transfer of
energies and type of energy required to shape materials.(13)
4. Explain the need for the development of unconventional AM-10 K3
machining process by considering any four simple cases of AM-11
your own interest.(13) ND-14
ND-15
5. Classify unconventional machining processes based on basic AM-11 K3
mechanism involved in the process and medium for transfer MJ-13
of energies and types of energy required to shape materials.(8)
6. Is unconventional machining process an alternate or AM-11 K2
complement to conventional machining process? Justify.(8) MJ-14
a. Demerits of conventional machining processes.
b. Need for unconventional machining processes.
c. Merits of unconventional machining processes.
7. Compare the process capabilities and limitations of electrical MJ-12 K2
energy based and mechanical energy based unconventional
machining processes.(8)
8. How are the unconventional machining processes classified? MJ-12 K4
9. What do you understand by the word ‘unconventional’ in MJ-12 K2
unconventional machining processes? Is it justified to use this
word in the context of the utilization of these processes on the
shop floor?

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10. What are the basic limitations of conventional manufacturing MJ-14 K3
process? Justify the need of conventional manufacturing
process in today’s industries.(13)
11. Classify the unconventional machining process.(8) ND-14 K3
ND-15
12. Discuss the recent developments in unconventional ND-14 K5
machining processes.(8)
13. Enumerate the classification of unconventional machining AM-15 K2
processes.(13) ND-15
14. Compare the process application of unconventional machining ND-15 K1
processes.(10)
15. Explain the factors that should be considered during the MJ-16 K3
selection of an appropriate unconventional machining process ND-16
for the given job for specific applications.(13) AM-17
AM-15
16. Differentiate conventional machining process with the MJ-16 K2
unconventional machining process.(8)
17. Explain the process capabilities and limitations of electrical; MJ-16 K1
mechanical, chemical and thermal energy based AM-18
unconventional machining processes.(13) MJ-13
18. How are the developments in the areas of materials for ND-16 K3
evolution of advanced machining techniques?(8)
19. Classify the unconventional machining process on the basis of ND-16 K4
type of energy employed, MRR transfer media and energy AM-18
resources used.(13)
20. Elaborate the classification of modern machining process on AM-17 K2
the basis energy employed. Discuss the mechanism of
material removed and energy transfer in each category.(8)
21. Why electro chemical process is found to be most potential AM-17 K4
process for gear finishing? Explain its principle, key process
parameter and other applications.(13)

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UNIT-II
MECHANICAL ENERGY BASED PROCESSES
PART-A
1. What are the advantages of ultrasonic machining? MJ-14 K2
2. Write the formula for material removal rate from the ductile MJ-14
and brittle material in abrasive jet machining (AJM).
3. Name any four process variables that control the material ND-14
rate in AJM process.
4. What are the applications of UCM process? ND-14
5. What are the principle of USM? AM-15
6. List the applications of WJM. AM-15
ND-16
7. Name any four abrasives used in AJM uses and mention ND-15
their recommended use.
8. What are the applications of USM process? ND-15
9. What are the parameters that influences the material MJ-16
removal rate in ultrasonic machining process?
10. Reuse of abrasives is not recommended in AJM. Why? MJ-16
11. List the different types of abrasives used in AJM. ND-16
12. Why AJM material is not recommended to machine ductile AM-17
materials?
13. Mention the functions of the horn in ultrasonic machining. AM-17
14. What is the principle of WJM? AM-18
15. What is ultrasonic machining? AM-18
PART-B
1. Explain the variables that are affecting the material removal MJ-14
rate and accuracy of abrasive jet machining process(13) MJ-16
2. Write short notes on the following related to Ultra sonic MJ-14
Machining (USM): AM-17
i. Transducer used in USM machine.(4)
ii. Functions of slurry and oscillator in USM.(4)
iii. Types of abrasive used in USM.(4)
iv. Grain size Vs. machining rate.(4)
3. Sketch the water jet cutting unit and also explain the ND-14
mechanism of jet cutting.(8) ND-15
4. Explain the mechanism involved in material removal in AJM ND-14
process.(8) AM-17
5. With a neat sketch, explain the working principle of ND-14
ultrasonic machining process.(8) ND-15
List the applications of ultrasonic machining process(8) MJ-16
ND-16
6. Discuss the various process parameters that control MRR in ND-14
USM process.(8) AM-17
7. Derive the equation for volumetric material removal rate AM-15
involved in grain throwing model of USM.(13)

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8. Compare the nozzle designs employed in AWJM with a neat AM-15
sketches.(4)
9. Briefly explain the process and working of abrasive jet ND-15
machining (8). AM-17
10. What are the variable that affect the cutting phenomena in ND-15
AJM process? And also explain the effect of two variables in
MRR.(10)
11. Discuss the apparatus, process parameters and process ND-16
capabilities and applications of abrasive-water jet
machining.(13)
12. Discuss the transducer and abrasives used in USM.(6) ND-16
13. Describe the principle and equipment for AWJM. Describe AM-18
the process capabilities and applications of AWJM.(13)
14. Give the principle of material removal in USM. Explain the AM-18
ultrasonic sinking and contour machining with neat
sketch.(6)
15. List the factors that affect the MRR in USM and write short AM-18
notes on each of them.(7)
UNIT III
ELECTRICAL ENERGY BASED PROCESSES
PART-A
1. What are the functions of dielectric fluid in Electrical MJ-14
Discharge machining (EDM)? ND-15
2. Name some of the tool material used in EDM. MJ-14
3. What are the etchants in chemical machining process? ND-14
4. List the advantages of ECM process. ND-14
5. Sketch the relaxation circuit of EDM. AM-15
6. State the principle of EDM. AM-15
7. List out the applications of wire cut EDM process. ND-15
8. State function of servo-mechanism in ‘Electric discharge MJ-16
machining (EDM) process.
9. List the desirable properties of a good dielectric fluid. MJ-16
10. List out the limitations in EDM. ND-16
11. What are the roles of dielectric fluid in EDM? ND-16
12. Name some of the most commonly used in dielectric fluids in AM-17
EDM.
13. Is electrochemically machined surface has improved fatigue AM-17
strength? Justify your answer.
14. What are the prime requirements of tool material in EDM? AM-18
15. Define W/T ratio. AM-18

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PART-B
1. Explain the following in electric discharge machining (EDM) MJ-14
with neat sketch:
a. Electrode feed control system.
b. Factors to be considered for EDM machine tool
selection.
2. Explain the following on wire EDM technology: MJ-14
i. Dielectric system(4)
ii. Deionized water(4)
iii. Positioning system(4)
iv. Wire drive system(4)
3. Explain with a neat sketch, the electro chemical grinding ND-14
process. And also list its applications.(10)
4. What is the principle of electro chemical honing process(6) ND-14
5. With the neat sketch, explain the chemical machining ND-14
process.(10)
6. List the advantages and limitations of CHM process.(6) ND-14
7. Explain the process of wire cut EDM with a neat sketch.(13) AM-15
ND-15
AM-17
8. Write the short notes on the following in the context of EDM. AM-15
Types of flushing(4) AM-18
Types of spark generators (4)
Types of electrode holders(4)
Properties of Dielectric.(4)
9. Explain the breakdown mechanism in EDM process.(8) ND-15
10. Discuss the various electrode materials used in EDM ND-15
process.(8)
11. Discuss the types of tool wear in EDM process.(8) ND-15
12. Explain the general arrangement of an electrical discharge MJ-16
machining process and list out the advantages, limitations
and applications.(13)
13. Describe the principle, construction and working of wire cut MJ-16
electrical discharge machining process (WCEDM) and state ND-16
its merits and demerits. (13)
14. Describe the construction and working principle of EDM ND-16
process. Write its advantages, disadvantages and
applications. Also, discuss the effect of process parameters
on the metal removal in EDM.(13)
15. Sketch and explain of metal removal in EDM process.(8) AM-17
16. Discuss briefly the types of spark erosion generators.(8) AM-17
17. Describe the wire cut EDM equipment, its working AM-18
applications and advantages.(13)
18. Explain in different types of control circuits used in EDM.(8) AM-18

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UNIT IV
CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
PART-A
1. What are the main functions of electrolysis in electro chemical MJ-14
machining (ECM)? ND-14
2. What are the parameters that affect the material removal rate MJ-14
in electro chemical grinding? ND-14
3. Write a short note on dielectric fluid used in EDM process. ND-14
4. List the applications of wire EDM process. ND-14
5. What is mean by maskant? AM-15
MJ-16
6. Mention the applications of ECH. AM-15
7. What are the etchants in chemical machining process? ND-15
8. Write the formula for finding MRR in ECM process. ND-15
9. Distinguish between electrochemical machining and MJ-16
electroplating process.
10. List the factors that affect MRR in ECM. ND-16
11. What are the advantages of ECG over conventional grinding? ND-16
12. What are different layers that can be identified in spark AM-17
eroded surface?
13. What do you understand by spark eroded surface? AM-17
14. What do you understand by charging an electrolyte? AM-17
15. Name any four methods generally used to filter the electrolyte. AM-18
16. What are the important functions of abrasive particles used in AM-18
ECG?
PART-B
1. Explain the following on Electro Chemical Machining Process MJ-14
with a suitable sketches. MJ-16
Cathode tool.(8)
Correction of tool.(8)
2. Compare the chemical Machining (CHM) with electro-chemical MJ-14
machining (ECM) with respect to their process
parameters.(13)
3. Explain the break down mechanism in EDM process.(8) ND-14
4. With a neat sketch, explain any two power circuits used in ND-14
EDM process.(8)
5. Discuss the types of tool wear in EDM process(8) ND-14
6. Explain with the neat sketch, the wire EDM process.(8) ND-14
7. With a neat sketch, explain the chemical machining ND-15
process.(10)
8. List the advantages and limitations of CHM process.(6) ND-15
9. Explain with the neat sketch, electro chemical grinding ND-15
process and also list its applications.(12) ND-16
10. What is the principle of ECH?(4) ND-15
11. Explain the process of chemical blanking and chemical milling AM-15
with neat sketches.(13)
ME6004 UNCONVENTIONAL MACHINING PROCESS Page 7
12. Explain the process of ECH with a neat sketch.(8) AM-15
13. Describe the process and principle of ECG with a neat AM-15
sketch.(8) AM-18
14. List the advantages and limitations of CHM process.(6) AM-15
15. Explain the electro chemical honing process with a neat MJ-16
sketch.(8) AM-18
16. Explain the followings with respect to chemical machining MJ-16
process :(8)
Characteristics of cut and peel maskants
Selections of maskants
limitations
17. Explain with neat sketch, explain the working of ECM ND-16
process. Also write its advantages, disadvantages and
applications.(13)
18. With the neat sketches, explain the principle of electro- ND-16
chemical grinding. State its process capabilities and
applications.(13)
19. During the machining of iron (Fe) using aqueous solution of AM-17
Nacl, what are the possible reactions at electrodes?(8)
20. Explain the principle of electro chemical deburring process.(8) AM-17
21. Discuss about the types of maskants used in chemical AM-17
machining.(8)
22. Explain the basis, why surface finish of a chemically AM-17
machined surface of an alloy is poor.(8)
23. Explain the ECM process with neat sketch and mention its AM-18
applications and advantages.(13)
UNIT V
THERMAL ENERGY BASED PROCESSES
PART-A
1. Compare the LBM with EBM. MJ-14
2. Write the advantages of plasma arc machining. MJ-14
3. What is the principle of electron beam machining process ND-14
4. Write the short notes on magnetic abrasive machining. ND-14
5. Name the beam control techniques of EBM. AM-15
6. What is mean by laser beam drilling? AM-15
7. What is principle of laser beam machining process? ND-15
8. List the applications of electron beam machining process. ND-15
9. State the working principal of plasma arc machining process. MJ-16
10. Why vacuum id needed in electron beam machining process? MJ-16
11. What do you mean by plasma? ND-16
12. What is the advantage of EBM over LBM? ND-16

ME6004 UNCONVENTIONAL MACHINING PROCESS Page 8


13. Is it possible to machine electrically non-conductive material AM-17
using EBM process? Justify your answer.
14. Why tungsten is not used as electrode material in plasma arc AM-17
cutting?
15. What is basic heating phenomenon that takes place in plasma AM-18
arc welding?
16. Write down the Richardson-Dushman equation. AM-18
PART-B
1. What are the parameters that are affecting the performance of MJ-14
plasma arc machining (PAM).(13)
2. With the neat sketch, explain the working principle, MJ-14
construction and process variables for laser beam machining
(LBM) process.(13)
3. Explain with the neat sketch, the principle of laser beam ND-14
machining process (LBM). And also list its merits, demerits AM-18
and applications.(13)
4. With the neat sketch, explain the process of plasma arc ND-14
machining.(10) ND-15
5. Discuss the parameters of plasma cutting. ND-14
6. With a neat sketch, explain the process of LBM along with the AM-15
effect of all the process parameters.
7. Explain the principle and working of PAM with a neat AM-15
sketch.(13) AM-18
8. Describe the process of EBM with a neat sketch.(8) AM-15
9. With the neat sketch, explain the process of electron beam ND-15
machining process (EBM). And also list its applications.(13) MJ-16
AM-18
10. What is LASER? Explain how it is used to machine the MJ-16
materials.(8)
11. Discuss the factors that influence the quality of the cut in MJ-16
plasma arc machining process.(8)
12. Explain the different types of plasma arc machining process ND-16
with a neat sketch. Also state its advantages, disadvantages
and applications.(13)
13. Explain the principles, machining system, process ND-16
capabilities, applications and advantages of EBM with a neat
sketch.(13)
14. Explain the product of laser beam and working principle of AM-17
LBM.
15. Compare the operation of transferred and non-transferred arc AM-17
mode in plasma machining.
16. Write a brief note on under water plasma cutting.(6) AM-17
17. Compare and contrast the working principle of AJM and AM-18
WJM. Mention their exclusive applications.(13)

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