Qa of Ucm

A u2007 Anna University B.
E Mechanical ME1001-UNCONVENTIONAL MACHINING PROCESS Question paper
Seventh semester, Mechanical engineering
ME1001 UNCONVENTIONAL MACHINING PROCESS
(Common to Mechanical Engineering and Production Engineering)
Time: 3 hours
Max Marks: 80
Answer any FIVE Questions.
All Questions carry equal marks
1. (a) Write a note on tool wear in ultrasonic machining process. [8]
(b) Explain the economic factors considered while selecting the ultrasonic machining process. [8]
2. (a) Explain Abrasive Jet Machining (AJM) with suitable diagram. [8]
(b)With a suitable sketch explain the tooling arrangement to produce one of the products for aircraft industry. [8]
3. (a) What are the various advantages of using ECM? [8]
(b)What are the various advantages Abrasive Jet Machining (AJM) [8]
4. Describe the advantages and limitations of power supply with rotary impulse generator circuit used in EDM. [8+8=16]
5. (a) what is plasma? How it can be used for material processing? [3+5]
(b) What are the different types of plasmotrons used in material cutting applications? [8]
6. (a) Discuss the factors influencing the choice of electrode material in EDM? [8]
(b) How the surface finish and accuracy of machining are influenced by the process parameters in EDM? [8]
PART – A UNIT I
Two Marks Questions (Part A questions)
1. What is meant by conventional machining processes?.
2. What is meant by Unconventional machining processes?
3. 1. What are thermal energy methods of unconventional machining?
4. What is electro chemical energy method of unconventional machining?
5. 2. What are chemical energy methods of unconventional machining?

6. 3. What are mechanical energy methods of unconventional machining?
7. 4. List the unconventional machining process which uses mechanical energy?
8. 5. List the unconventional machining process, which uses thermal or heat energy?
9. 6. List the unconventional machining process which uses Electro chemical energy?
10. 7. What are the characteristics of unconventional machining process?.
11. 8. Name the unconventional machining processes which are used to remove max control?
12. 9. Name the unconventional machining processes which produce best surface finish?
16 Marks Questions (Part B Questions)
13. Compare the mechanical and electrical energy processes in terms of physical parameters. Shape capabilities, Process
capability, and Process economy. (16)
14. Explain the reasons for the development of Unconventional Machining Process. Discuss about the criteria recommended in
selection of these processes. (16)
15 Make a comparison between traditional and unconventional machining processes in terms of cost, application, scope,
Machining time, advantages and limitations. (16)
16 For different non-conventional processes, present in the form of a table, various process parameters recommended (16)
PART – A UNIT II
1. State the working principle of Abrasive Jet Machining.
2. 10. What are the abrasives used in AJM process?
3. 11. What are the materials used for nozzle manufacturing in AJM process?
4. 12. Name the carrier gases used in AJM process?
5. 13. What is the transfer medium in AJM?
6. 14. What are the desirable properties of carrier gas in AJM.
7. 15. Define AJM?
8. 1. How does AJM differ from conventional sand blasting process?
9. 2. What are the advantages of AJM process?
10. What are the applications of AJM?.

11. Write the Disadvantages of AJM process?
12. Give the formula for find the material remove rate for brittle metal?
13. Give a summary of the abrasive of their application for different operation?
14. Write the formula for find the MRR for ductile materials?
15. What are the Process parameters affecting the MRR in AJM?
16. What are the disadvantages of using abrasives again and again?
17. What are the different types of nozzles heads used in AJM?
18. Why oxygen should not be used in AJM?
19. What are the different types abrasives used in AJM?
20. Reuse of abrasives is not recommended in AJM. Why?
21. What are the properties of water jet machining about effect cutting action?
22. What are the types of units and its purpose used in water jet cutting system?
23. Why we are using the diamond nozzle?
24. Why do you select proper cutting fluid in WJM?
25. Does there is any environmental effects while using the water jet machining?
26. What are the advantages of WJC over conventional cutting methods?
27. What are the applications of WJM?
28. What are the commonly used additives in WJM?
29. What is optical tracing system?
30. What is ultrasonic machining?
31. What are the advantages of USM?
32. What are the Disadvantages of USM?
33. What are the applications of USM?
34. What are the components of USM?
35. What is ultrasonic transducer?
36. Write short noted on piezoelectric crystals?
37. What is magneto strictive effect?

38. What are the magneto strivtive materials employed in USM?
39. What is the purpose of concentrator used in USM?
40. What is abrasive Slurry?
41. What are the different types of concentrators?
42. What are the characteristics of carrier fluid?
43. What are the elements of Carrier Fluid?
44. What are the types of feed mechanisms used in USM?
45. What is the principle of WJM?
46. (i) Explain the principle of AJM. Mention some of the specific applications. (6)
(ii) Discuss in detail about the AJM process variables that influence the rate of material
Removal and accuracy in the machining. (10)
47. (i) Explain the method of AJM with help of schematic diagram. (10)
(ii) Mention the advantages and limitations of AJM. (6)
48. Explain the process parameters in WJM processes. (16)
49. With neat sketch explain the process of AJM .List its application and limitations. (16)
50. (i) Explain the process parameters that influence WJM. List the applications and limitations
of WJM (10)
(ii) Briefly discuss the application and limitation of WJM. (6)
51. Explain the USM machine setup an discuss various feed mechanisms. (16)
52. (i) Discuss the influence process parameters and applications of USM (10)
(ii) Give a note o the various types of transducers. (6)
PART – A UNIT III
1. Define electrical discharge machining?

2. 16. What are functions of dielectric fluid used in EDM?
3. 17. Basic requirement of dielectric fluid used in EDM?
4. 18. What the dielectric fluids commonly used in EDM?
5. 19. What are the prime requirements of tool material in EDM?
6. 3. Name some of the tool material used in EDM?.
7. 4. What is the process parameter efficiency the MRR?
8. 5. Write the formula for finding the energy discharge in EDM?
9. 6. What is the effect of capacitance in EDM?
10. How do you increase the inductance of the circuit?
11. 20. Define W/T ratio?
12. What is cycle time?
13. Define over cut?
14. Define Rehardening?
15. What is recast metal?
16. Explain electrode wear?
17. What are types of power supply circuits used in EDM?
18. What are the design factors to be considered while selecting the machine tool?
19. Why the servo controlled system is needed in EDM?
20. Define wear ratio?
21. What are the functions of adaptive control used for EDM?

22Explain the EDM process, its process parameters and applications(16)
23. Describe the wire cut EDM equipment, its working, applications and advantages (16)
24. (i) With the help of neat sketch, Describe the EDM process. (12)
(ii) Explain briefly advantages of wire EDM process. (4)
25. (i) Explain the classification and characteristics of various spark erosion generators. (8)
(ii) With help of neat sketch describe the mechanism of material removal in EDM. (8)
26. (i) Explain the working principle, elements and characteristics of wire EDM. (10)
(ii) Explain how the stratified wire works. Also discuss about the recent developments in wire EDM. (6)
PART – A UNIT IV
1. 7. Define ECM?
2. 8. Write the Faraday’s first law of electrolysis?
3. 9. Write the Faraday’s second law of electrolysis?.
4. 10. Write Ohm’s law?
5. 11. What are the factors that influence oxidation in ECM?
6. 12. What are the materials used to make the tool electrode?
7. 13. What are the main functions of electrolysis in the ECM?
8. 14. What are the properties are expected from the electrolysis used in the ECM?
9. 15. What are the electrolysis commonly used in ECM?
10. 16. What are the results which is in improper selection of electrolyte in ECM?
11. 17. What are the methods generally used to filter the electrolyte?
12. 18. What are the characteristics of a good ECM tool?
13. 19. What are the parameters that affect the MRR?
14. 20. How the current density affect the MRR?
15. 21. What are the advantages of ECM?
16. 22. What are the limitations of ECM?
17. 23. What are the applications of ECM?
18. 24. Define ECG.
19. 25. Which material is used to make the grinding wheel?
20. 26. What are the important functions of abrasive particles used in ECG?
21. 27. What are the advantages of ECG?
22. 28. What are the disadvantages of ECG?

23. 29. What are the limitations of ECG?
24. 30. What is the application of ECG?
25. 31. What is the self adjusting feature in ECM?
26. 32. What do you understand by “Etch Factor”?
27. (i) Describe the chemistry involved in ECM process. (8)
(ii) Briefly discuss about the effect of high temperature and pressure of electrolyte on the ECM process. (4)
(iii) Discuss about the economics of ECM. (4)
28. (i) Describe the working principle and elements of chemical machining. What are the
factors on which the selection of a resist for use in chemical machining? (10)
(ii) What are the specific advantages of using chemical machining over electrochemical
machining? Give some of the practical applications of chemical machining process. (6)
29. (i) Explain the principle of ECG with sketch. (8)
(ii) List out the advantage of EGC over conventional grinding. (4)
(iii) Mention the product application of ECG. (4)
30. Explain in detail the ECM process with neat sketch and also mention the advantages and application. (16)
31. (i) Describe the process of electrochemical machining. (8)
(ii) Discuss about the electrochemical honing and electrochemical grinding (8)
PART – A UNIT V
1. 33. What is Laser?
2. 34. What is the principle of LBM?

3. 35. What are the characteristics of Laser beam?
4. 36. What are the gases commonly used in LASER?
5. 37. What are the advantages of Laser drilling?
6. 38. What are the characteristics of Laser used in Laser machining?
7. 39. What are the fundamentals of photons used in Laser?
8. 40. What are the emission lines?
9. 41. What is the Maser principle?
10. What is population inversion?
11. How does Laser melting works?
12. What is solid state Laser?
13. Define plasma.
14. What are the advantages of plasma arc welding?
15. What are the metals that can\'t be machined by plasma arc machining?
16. What is the basic heating phenomenon that takes place in plasma arc welding?
17. How does the basic plasma is generated?
18. How the initial ionization is accomplished in plasma arc machining?
19. Why does gas formed in plasma do in P.A.M?
20. How another source of heating achieved in P.A.M?
21. Write the principle of P.A.M
22. Write the circuitry details in PAM.
23. Which type of power supply is used in P.A.M?
24. Which part is constricted by plasma?
25. Describe the commonly used gas mixture in PAM and their corresponding work materials.
26. Can you machine electrically non-conducting materials using EBM process?
27. What is the function of water muffler in PAM?

28. Explain the process of LBM and PAM with neat sketches. (8)
29. (i) Discuss the process parameters of EBM and their influence on machining quality. (8)
(ii) Explain the process capabilities of EBM and PAM. (8)
30. (i) Explain the principle of LBM with neat sketch. (10)
(ii) List out the advantage and limitation of LBM process. (6)
31. (i) Explain the principle of PAM with sketch (10)
(ii) List out the advantage and limitation of PAM process. (6)
32. (i) Mention the application of EBM. (4)
(ii) What is EBM? Sketch its set up and indicate its main parts and explain the principle of operation. (12)
33. (i) Explain the principles and elements of EBM, also how the work table is protected from getting damaged by electron
beam. (8)
(ii) Discuss how the process variables influence MRR, HAZ & the applications in the LBM process..(8)
Unconventional Machining Processes previous question papers JNTU
Unconventional Machining Processes previous question papers JNTU - 1
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
1. (a) With the help of a neat sketch, explain how material is removed from a work
piece in ultrasonic machining process. [4+4=8]
(b) Explain the various factors affecting the material removal rate in ultrasonic
machining process. [8]
2. (a) Explain the process of Water Jet Machining with a neat sketch. [8]
(b) Compare the specific energy consumption by PAM and WJM [8]
3. How do the surfaces produced by Chemical Machining, Electro Chemical Machining

and conventional grinding compare? What are the .reasons for obtaining differences
in the surface finish? [16]

(b) What are the various limitations of ECM? [8]
5. Explain the various industrial applications of Electric Discharge Machining (E.D.M.)
with examples. [8+8]
1. Describe the effects of the following machining parameters on the material removal
rate in Ultrasonic machining.
(a) Viscosity of fluid in slurry [8]
(b) Mean grain diameter [8]
2. (a) Explain the principle used in abrasive water jet machine. [8]
(b) Explain the characteristics of water jet cutting process. [8]
3. (a) Compare Electro Chemical Machining with a single point machining and de-
scribe the differences. [4+4=8]
(b) What are the limitations and industrial applications of Electro Chemical Ma-
chining? [4+4=8]
4. (a) What is the influence of Electro Chemical Machining on the Mechanical properties
of machined components.? [8]
6. (a) What are the advantages and disadvantages of E.D.M. process -explain in
detail. [4+4]
(b) With neat sketch, explain the closed loop hydraulic circuit used in E.D.M.
process. [4+4]
7. (a) Discuss the main industrial applications of plasma cutting systems. [8]
(b) What are the advantages and disadvantages of plasma cutting process? [4+4]
8. With the help of a neat sketch explain the construction, principle of operation,
advantages, disadvantages and applications of expanding type of electro-magnetic
forming process. [3+3+3+3+4]
UNCONVENTIONAL MACHINING PROCESS JNTU previous years question papers

1. (a) With the help of a neat sketch, explain how material is removed from a work piece in ultrasonic machining process.
[4+4=8]
(b) Explain the various factors affecting the material removal rate in ultrasonic machining process. [8]
2. (a) Describe the role of nozzle in water jet machining. [8]

(b) Explain how the distance between nozzle and work piece influence the material removal rate. [8]
3. (a) Distinguish between flow masking and spray masking. When are they preferred? [4+4]
(b) Describe production of a Printed Circuit Board using Chemical Machining. What are the precautions required in this case?
[4+4]

5. What are the different modes of dielectric flushing used in E.D.M. Which method of flushing the inter electrode gap yields
improved M.R.R. and why? [5+2+9]
6. (a) What are the various process parameters which influence the MRR? [8]
(b) What materials are used for Electrodes? Mention the relative advantages.
[4+4]
7. (a) What is plasma? How it can be used for material processing? [3+5]
(b) What are the different types of plasmotrons used in material cutting applica-
tions? [8]
1. (a) With the help of a neat sketch, explain how material is removed from a work piece in ultrasonic machining process.
[4+4=8]
(b) Explain the various factors affecting the material removal rate in ultrasonic machining process. [8]

[4+4]
6. (a) What are the various process parameters which influence the MRR? [8]
(b) What materials are used for Electrodes? Mention the relative advantages.
[4+4]
(b) What are the different types of plasmotrons used in material cutting applica-
tions? [8]
1. (a) With the help of a neat sketch, explain how material is removed from a work
piece in ultrasonic machining process. [4+4=8]
(b) Explain the various factors affecting the material removal rate in ultrasonic
machining process. [8]
2. (a) Name the carrier gases used in abrasive jet machining? [5]
(b) What is the range of carrier gas pressure required in abrasive jet machining?
[5]
(c) Describe the effects of abrasive flow rate on material removal rate in AJM.[6]
3. (a) With suitable sketches explain the metal removal mechanism in Electro Chem-
ical Grinding. [4+4]
4. (a) Trace the developments of Chemical Machining and indicate early applica-
tions. [4+4]
(b) How are the deficiencies observed with the early applications of Chemical
Machining overcome subsequently? [8]
5. What are the different modes of dielectric flushing used in E.D.M. Which method
of flushing the inter electrode gap yields improved M.R.R. and why? [5+2+9]
6. Describe the advantages and limitations of power supply with rotary impulse generator circuit used in EDM. [8+8]
(b) What are the different types of plasmotrons used in material cutting applications? [8]
KINGS
COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
SUB: ME1001-UNCONVENTIONAL MACHINING PROCESS YEAR/SEM:III/VI
QUESTION BANK
UNIT-I (INTRODUCTION)
PART-A (2 MARKS)
1. What is necessity for unconventional machining processes?
2. How non-traditional machining processes are classified?
3. Enlist the requirement that demands the use of advanced machining process.
4. Why unconventional mechanical machining process is not so effective on soft metals like
aluminum?
PART-B (16 MARKS)
1. (i) Explain the factors that should be considered during the selection of an appropriate
unconventional machining process for a given job. (8)
(ii) Compare and contrast the various unconventional machining process on the basis of
type of energy employed, material removal rate, transfer media and economical aspects. (8)
UNIT II(MECHANICAL ENERGY BASED PROCESSES)
PART-A (2 MARKS)
1. Define AJM?
2. What are the advantages of AJM process?
3. What are the applications of AJM?
4. Write the Disadvantages of AJM process?
5. Give a summary of the abrasive of their application for different operation?
6. What are the Process parameters affecting the MRR in AJM?
7. What are the different types abrasives used in AJM?
8. Reuse of abrasives is not recommended in AJM. Why?
9. What are the properties of water jet machining about effect cutting action?
10. What are the advantages of WJC over conventional cutting methods?
11. What are the applications of WJM?
ME1001-UNCONVENTIONAL MACHINING PROCESS
Kings college of engineering /Mechanical/ question bank/page no 2
12. What are the commonly used additives in WJM?
13. What is optical tracing system?
14. What is ultrasonic machining?
15. What are the advantages of USM?
16. What are the Disadvantages of USM?
17. What are the applications of USM?
18. What is ultrasonic transducer?
19. What are the magnetostrivtive materials employed in USM?
20. What is the purpose of concentrator used in USM?
PART-B (16 MARKS)
1. (i) Explain the principle of AJM. Mention some of the specific applications. (6)
(ii) Discuss in detail about the AJM process variables that influence the rate of material
removal and accuracy in the machining. (10)
2. (i) Explain the method of AJM with help of schematic diagram. (10)
(ii) Mention the advantages and limitations of AJM. (6)
3. Explain the process parameters in WJM processes. (16)
4. With neat sketch explain the process of AJM .List its application and limitations. (16)
5. (i) Explain the process parameters that influence WJM.List the applications and limitations
of WJM (10)
(ii) Briefly discuss the application and limitation of WJM. (6)
6. Explain the USM machine setup an discuss various feed mechanisms (16)
7. (i) Discuss the influence process parameters and applications of USM (10)
(ii) Give a note o the various types of transducers. (6)
UNIT-III (ELECTRICAL ENERGY BASED PROCESSES)
PART-A(2 MARKS)
1. Define electrical discharge machining?
2. What are functions of dielectric fluid used in EDM?
3. Basic requirement of dielectric fluid used in EDM?
4. What the dielectric fluids commonly used in EDM?
5. Name some of the tool material used in EDM?
6. What is the process parameter efficiency the MRR?
7. Explain electrode wear?
8. What are types of power supply circuits used in EDM?
9. What are the design factors to be considered while selecting the machine tool?
PART-B (16 MARKS)
1. Explain the process of electrical discharge machining, its process parameters (16)
and applications.
2. Describe the wire cut EDM equipment, its working, applications and advantages (16)
3. (i) With the help of neat sketch, Describe the EDM process. (12)
(ii) Explain briefly advantages of wire EDM process. (4)
4. (i) Explain the classification and characteristics of various spark erosion generators. (8)
(ii) With help of neat sketch describe the mechanism of material removal in EDM. (8)
5. (i) Explain the working principle, elements and characteristics of wire EDM. (10)
UNIT-IV (CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES)
PART-A (2 MARKS)
1. Define ECM?
2. What are the factors that influence oxidation in ECM?
3. What are the materials used to make the tool electrode?
4. What are the main functions of electrolysis in the ECM?
5. What are the properties are expected from the electrolysis used in the ECM?
6. What are the parameters that affect the MRR?
7. What are the advantages of ECM?
8. What are the limitations of ECM?
9. What are the applications of ECM?
10. Which material is used to make the grinding wheel?
11. What are the advantages of ECG?
12. What are the disadvantages of ECG?
13. What are the limitations of ECG?
14. What is the application of ECG?
PART-B(16 MARKS)
(ii) Briefly discuss about the effect of high temperature and pressure of electrolyte on
the ECM process. (4)
(ii) What are the specific advantages of using chemical machining over electro
chemical machining? Give some of the practical applications of chemical machining process(6)
3. (i) Explain the principle of ECG with sketch. (8)
(ii) List out the advantage of EGC over conventional grinding. (4)
(iii) Mention the product application of ECG. (4)
4. Explain in detail the ECM process with neat sketch and also mention the advantages
and application. (16)
5. (i) Describe the process of electrochemical machining. (8)
(ii) Discuss about the electrochemical honing and electrochemical grinding. (8)
UNIT-V (THERMAL ENERGY BASED PROCESSES)
PART-A (2 MARKS)
1. What is Laser?
2. What are the characteristics of Laser beam?
3. What are the gases commonly used in LASER?
4. What are the characteristics of Laser used in Laser machining?
5. Define plasma.
6. What are the advantages of plasma arc welding?
7. What are the metals that can't be machined by plasma arc machining?
8. How does the basic plasma generated?
9. Write the principle of P.A.M
10. Define EBM?
11. What is the characteristic of the electron beam?
12. What are the main elements of the EBM equipment?
13. Write the advantage of EBM?
14. Write the disadvantages of EBM?
15. Write any four application of EBM?
Kings
1. Explain the process of LBM and PAM with a neat sketch. (16)
2. (i) Discuss the process parameters of EBM and their influence on machining quality. (8)
(ii) Explain the process capabilities of EBM and PAM. (8)
3. (i) Explain the principle of LBM with neat sketch (10)
(ii) List out the advantage and limitation of LBM process (6)
4. (i) Explain the principle of PAM with sketch (10)
(ii) List out the advantage and limitation of PAM process. (6)
5. (i) Mention the application of EBM (4)
(ii) What is EBM? Sketch its set up an indicate its main parts and explain the principle
of operation. (12)
6. (i) Explain the principles and elements of EBM, also how the work table is protected
From getting damaged by electron beam. (8)
(ii) Discuss how the process variables influence MRR, HAZ and pattern generation. (8
Model Q of different units
b) How the surface finish and accuracy of machining are influenced by the process parameters in EDM? [8]
Explain any one method of producing laser

3. How do the surfaces produced by Chemical Machining, Electro Chemical machining
and conventional grinding compare? What is the .reasons for obtaining differences
in the surface finish? [16]

[4+4]
2. (a) Name the carrier gases used in abrasive jet machining? [5]
(b) What is the range of carrier gas pressure required in abrasive jet machining?[5]
1. (i) Explain the factors that should be considered during the selection of an appropriate
unconventional machining process for a given job. (8)
(ii) Compare and contrast the various unconventional machining process on the basis of
type of energy employed, material removal rate, transfer media and economical aspects. (8)

(ii) Briefly discuss about the effect of high temperature and pressure of electrolyte on
the ECM process. (4)

(ii) What are the specific advantages of using chemical machining over electro
chemical machining? Give some of the practical applications of chemical machining process(6)
(ii) Discuss about the electrochemical honing and electrochemical grinding. (8)
------------------------------------------------------------------------------------------------------------------------------------------
Explain the features of EBM unit.
Explain the effect of increasing the acceleration potential on MRR in EBM
Compare the USM, WJM, and AJM in terms of process capabilities and limitations
Discuss about the of process parameters of LBM, ECM and PAM at its influence in machining Quality.
Compare the mechanical, electrical energy in terms of physical parameters, shape capabilities, process capabilities and process
economy.
Compare plasma arc machining with gas cutting
Explain the following in detail.
1) Types of transducers used in USM

2) Feed mechanisms in USM
3) Applications of USM
4) Abrasives in USM
USM is used for drilling a hole in aluminium and cast iron under same conditions. Which one will have higher depth drilled and
justify.
Discuss the effect of high temperature and pressure of electrolyte in the ECM process.
Explain how a complex shapes can be cut using EBM process.
Write a note about the underwater plasma arc cutting system
Briefly explain the over view of the unconventional machining process.
Why this machining is essential for industries.
Briefly explain the following machining parameters and how they are affecting the machining performance of USM
1) Frequency of vibrations
2) Grain size
3) Apply static load
4) Slurry, tool and work material
Discuss the factors to be considered for selecting the electrode in the EDM process.
Explain the ECM process. Explain how a replica of the is obtained.
Explain any one method of producing laser.
Write the thermal effects of PAM process.
Explain the features of EBM unit
Explain the effect of increasing the acceleration potential on MRR of EBM
Explain the USM machining setup and discuss various feed mechanism.
Explain the reasons for the development of UCM processes
Discuss about the criteria recommended in selection of these parameters
(ii) Discuss how the process variables influence MRR, HAZ and pattern generation. (8)
Model exam UCM SET 1
(2 Marks)
1) What is meant by unconventional machining process?

2) What are the different types of energies used in the unconventional machining processes?
3) What are the different types of material used for the nozzles in the USM process?
4) Name the different types of carrier gases used in the AJM process?
5) What are the properties of dielectric fluids used in the EDM process?
6) Define over cut in the EDM process?
7) What are the functions of electrolytes used in ECM process?
8) Name some etchants & Maskants in the CHM process?
9) What is laser?
10) Which are the materials that cannot be machined by PAM process?
(16 Marks)
11(a) Make a comparison between conventional and unconventional machining processes in terms of cost, application, scope,
(Or)
11(b). Explain the reasons for the development of Unconventional Machining Process. Discuss about the criteria recommended in
12(a)(i) Compare the USM, WJM and AJM in terms of process capabilities and limitations?(8)
12(a)(ii) briefly explain the following parameters and how they are affecting the machining performance in the USM
process?(8)
2) Grain size
(Or)
12(b) explain the following in detail?(16)
1) Type of transducers in USM

2) Feed mechanism in USM
4) Abrasives in USM
13(a)(i) discuss the factors to be considered for selecting the electrodes and the materials in the EDM process?(8)
13(a)(ii) describe different types of spark erosion generators used in the EDM process and write the limitations of each?(8)
(Or)
13(b)(i) write about different types of dielectric fluids used in the EDM process?(4)
13(b)(ii) describe the wire EDM equipment, its working, advantages, disadvantages and applications of the same?(12)
14(a)(i) compare the machining process of ECG against the conventional grinding?(6)
14(a)(ii) what are the specific advantages of the chemical machining over the ECM process? Give some practical applications of
the CHM process?(10)
(Or)
14(b)(i) discuss about the ECG & ECH process?(10)
14(b)(ii) discuss about the economics of the ECM process?(6)
15(a)(i) explain the features of EBM process?(4)
15(a)(ii) explain the process capabilities & the applications of EBM and PAM?(12)
(Or)
15(b) discuss the process parameters & capabilities of LBM & PAM?(16)
Model exam UCM SET 2

(2 Marks)
1) Enlist the requirements of the unconventional machining process?

2) Why unconventional machining processes cannot be effective on soft materials like aluminium?
3) What are the different types of transfer mediums used in the unconventional machining processes?
4) What are the applications of the WJM process?
5) Name some tool materials used in the EDM process?
6) What are the functions of dielectric fluids in the EDM process?
7) What are the abrasive materials used in the ECG process?
8) Explain the working principle of the ECH process?
9) What are the elements of the EBM equipments?
10) Explain the function of the reflective & the partially reflective materials in the PAM process?
(16 MARKS)
(Or)
11(b) For different unconventional processes, present in the form of a table, various process parameters recommended (16)
12(a)(i) explain the USM machining set up with a neat sketch , its applications?(8)
12(a)(ii) discuss the various feed mechanism used in the USM process?(8)
(Or)
12(b)(i) explain the role of nozzles in the AJM process?(4)
12(b)(ii) explain how the distance between the nozzle and the workpiece influence the MRR in WJM?(4)
12(b)(iii) explain the process parameters which affect the MRR and the applications of the USM process?(8)
13(a)(i) with a help of neat sketch describe the mechanism of MRR in EDM process?(8)
13(a)(ii) explain the working method , the elements and the characteristics of the wire EDM ?(8)
(Or)
13(b)(i) explain the working process of EDM, also write the process parameters and the applications(8)
13(b)(ii) describe how the surface finish and the MRR influenced by various process parameters of wire cut EDM?(8)
14(a)(i) explain the ECM process? Explain how a replica is obtained?(10)
14(a)(ii) discuss the effect of high temperature and pressure of electrolyte in the ECM process?(6)
(Or)
14(b)(i) compare ECM with a single point tool and describe the difference between both?(10)
14(b)(ii) what are the applications & limitations of ECH process?(6)
15(a)(i) explain the effect of increasing the acceleration potential on MRR in EBM?(4)
15(a)(ii) compare plasma arc machining with conventional gas cutting?(6)
15(a)(iii) explain any one method of producing laser?(6)
(Or)
15(b)(i) explain how the process variables which influence the MRR in the PAM process?(4)
15(b)(ii) explain the principle & applications of LBM process?(12)
ANSWERS OF MODEL EXAM QUESTIONS
11(b). Explain the reasons for the development of Unconventional Machining Process. Discuss about the criteria recommended in
Unconventional manufacturing processes are defined as a group of processes that remove excess material by various
techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a
sharp cutting tools as it needs to be used for conventional manufacturing processes.
Extremely hard and brittle materials are difficult to machine by traditional machining processes such as turning, drilling, shaping
and milling. Unconventional manufacturing machining processes, also called advanced manufacturing processes, are employed
where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below.
 Very hard fragile materials difficult to clamp for traditional machining

 When the workpiece is too flexible or slender
 When the shape of the part is too complex
Several types of Unconventional machining processes have been developed to meet extra required machining conditions.
When these processes are employed properly, they offer many advantages over conventional machining processes. The
traditional machining processes rely on harder tool or abrasive material to remove the softer material whereas in
Unconventional machining processes such as EDM uses electrical spark or thermal energy to erode unwanted material in order
to create desired shape. So, the hardness of the material is no longer a dominating factor.
Criteria recommended in selection of these processes:
Situations where traditional machining processes are Unsatisfactory or uneconomical:
 Work piece material is too hard, strong or tough.

 Work piece is too flexible to resist cutting forces or too difficult to clamp.
 Part shape is very complex with internal or external profiles including small holes.
 Requirements for surface finish and tolerances are very high.
 Temperature rise or residual stresses are undesirable, unacceptable after processing.
12(a)(i) Compare the USM, WJM and AJM in terms of process capabilities and limitations?(8)
12(a)(ii) briefly explain the following parameters and how they are affecting the machining performance in the USM
process?(8)
6) Grain size
(Or)
12(b) explain the following in detail?(16)
5) Type of transducers in USM

6) Feed mechanism in USM
8) Abrasives in USM
13(a)(i) discuss the factors to be considered for selecting the electrodes and the materials in the EDM process?(8)
13(a)(ii) describe different types of spark erosion generators used in the EDM process and write the limitations of each?(8)
(Or)
13(b)(i) write about different types of dielectric fluids used in the EDM process?(4)
13(b)(ii) describe the wire EDM equipment, its working, advantages, disadvantages and applications of the same?(12)
14(a)(i) compare the machining process of ECG against the conventional grinding?(6)
14(a)(ii) what are the specific advantages of the chemical machining over the ECM process? Give some practical applications of
the CHM process?(10)
(Or)
14(b)(i) discuss about the ECG & ECH process?(10)
14(b)(ii) discuss about the economics of the ECM process?(6)
15(a)(i) explain the features of EBM process?(4)
15(a)(ii) explain the process capabilities & the applications of EBM and PAM?(12)
(Or)
15(b) discuss the process parameters & capabilities of LBM & PAM?(16)
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A u2007 Anna University B.

E Mechanical ME1001-UNCONVENTIONAL MACHINING PROCESS Question paper

Seventh semester, Mechanical engineering

ME1001 UNCONVENTIONAL MACHINING PROCESS

(Common to Mechanical Engineering and Production Engineering)

Answer any FIVE Questions.

All Questions carry equal marks

1. (a) Write a note on tool wear in ultrasonic machining process. [8]

3. (a) What are the various advantages of using ECM? [8]

Two Marks Questions (Part A questions)

1. What is meant by conventional machining processes?.

2. What is meant by Unconventional machining processes?

3. 1. What are thermal energy methods of unconventional machining?

4. What is electro chemical energy method of unconventional machining?

5. 2. What are chemical energy methods of unconventional machining?

7. 4. List the unconventional machining process which uses mechanical energy?

10. 7. What are the characteristics of unconventional machining process?.

16 Marks Questions (Part B Questions)

Two Marks Questions (Part A questions)

1. State the working principle of Abrasive Jet Machining.

2. 10. What are the abrasives used in AJM process?

4. 12. Name the carrier gases used in AJM process?

5. 13. What is the transfer medium in AJM?

6. 14. What are the desirable properties of carrier gas in AJM.

7. 15. Define AJM?

8. 1. How does AJM differ from conventional sand blasting process?

9. 2. What are the advantages of AJM process?

10. What are the applications of AJM?.

18. Why oxygen should not be used in AJM?

19. What are the different types abrasives used in AJM?

20. Reuse of abrasives is not recommended in AJM. Why?

23. Why we are using the diamond nozzle?

24. Why do you select proper cutting fluid in WJM?

27. What are the applications of WJM?

28. What are the commonly used additives in WJM?

29. What is optical tracing system?

30. What is ultrasonic machining?

31. What are the advantages of USM?

32. What are the Disadvantages of USM?

33. What are the applications of USM?

34. What are the components of USM?

35. What is ultrasonic transducer?

36. Write short noted on piezoelectric crystals?

37. What is magneto strictive effect?

39. What is the purpose of concentrator used in USM?

40. What is abrasive Slurry?

41. What are the different types of concentrators?

42. What are the characteristics of carrier fluid?

43. What are the elements of Carrier Fluid?

44. What are the types of feed mechanisms used in USM?

45. What is the principle of WJM?

16 Marks Questions (Part B Questions)

Removal and accuracy in the machining. (10)

(ii) Mention the advantages and limitations of AJM. (6)

48. Explain the process parameters in WJM processes. (16)

(ii) Briefly discuss the application and limitation of WJM. (6)

(ii) Give a note o the various types of transducers. (6)

PART – A UNIT III

Two Marks Questions (Part A questions)

1. Define electrical discharge machining?

3. 17. Basic requirement of dielectric fluid used in EDM?

4. 18. What the dielectric fluids commonly used in EDM?

5. 19. What are the prime requirements of tool material in EDM?