Machining processes

Two Marks Questions and Answers

1. What is a lathe?
Lathe is a machine, which removes the metal from a piece of work to the required shape &size.
2. What is the various operations can be performed on a lathe?
1. Turning 6. Thread cutting 11. Grooving
2. Facing 7. Drilling
3. Forming 8. Boring
4. Knurling 9. Recessing
5. Chamfering 10. Tapping
3. What are principle parts of the lathe?
Red, headstock, tailstock, carriage, cross slide, tool post
4. What are the types of headstock?
Back geared type, all geared type

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5. State the various parts mounted on the carriage?
Saddle, compound rest, cross slide, tool post
6. What are the four types of tool post?
1. Single screw
2. Four bolt
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3. Open side
4. Four way
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7. What is an apron?
The integral part of several gears, levers clutches mounted with the saddle for moving the garriage along
with lead screw while thread cutting.
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8. State any two specification of lathe?

1. The height of centers from the bed
2. The maximum length of the bed
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9. List any five types of lathe?

1. Engine lathe 4. Bench lathe
2. Tool room lathe 5. Semi-automatic lathe
3. Automatic lathe
10. What is a semi-automatic lathe?
The lathe in which all the machining operations are performed automatically and loading and unloading of
work piece, coolant on or off is performed manually
11. What is copying lathe?
The tool of the lathe follows a template or master through a stylus or tracer

12. State the various feed mechanisms used for obtaining automatic feed?
1. Tumbler gear mechanism
2. Quick change gearbox
 3. Tumbler gear- Quick change gearbox
4. Apron mechanism
13. List any four holding devices?
1. Chucks 3. Centers
2. Face plate 4. Angle plate
14. What are the different operations performed on the lathe?
Centering, straight turning, rough turning, finish turning, shoulder turning, facing, chamfering, knurling,
etc
15. Define the term ‘Conicity’?
The ratio of the difference in diameters of tapers its length,
K= D-d/l
d- smaller dia
D-bigger dia
l- length of the work piece

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16. State any two specifications of capston lathe & turret lathe?
1. Number of spindle speed
2. Number of feeds for the turret or saddle
17. Compare the advantage of capston lathe & turret lathe?
1. Heavier & larger work piece chucking can be done
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2. More rigid hence it withstand heavy cuts
18. What is tooling?
Planning of operations sequence & preparation of turret or capston lathe are termed as tool- layout or
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tooling
19. What are the three stage of a tool-layout?
1. Planning & scheduling
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2. Detailed sketching of various machining operation sequence

3. Sketching the plan showing various tools
20. What are the different drives used in copying lathe?
1. Mechanical drives 3. Hydraulic drives
2. Air drives
21. What are the components that can be turned on a copying lathe?
1. Cam shaft 3. Journal bearings
2. Crank shaft
22. What is Shaper?
The machine, which is having a reciprocating type of machine tool with a single point cutting tool, used to
produce flat surfaces called as Shapers
23. List any four important parts of a Shaper?
Table, Tool head, Ram, Cross rail
24. How the feed & depth of cut is given to the shaper?
Feed is given by rotating the down feed screws of tool head depth of cut is given by rotating by raising or
elevating the table
25. Mention any four-shaper specification?
1. Maximum length of stroke
2. Type of driving mechanism
3. Power of the motor
4. Speed &feed available
26. How the planer differs from the shaper?
In planner-the work reciprocate while the tool is stationary
In shaper-the tool reciprocate while the work is stationary
27. State the use of planer?
The planer is used for machining heavy & large casting Ex. lathe bed ways, machine guide ways
28. List the various types of planners?

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1. Double housing 4. Open side planer
2. Pit planer 5. Edge planer
3. Divided table planer
29. Name the various parts of a double housing planer?
1. Bed 2.Table
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3.Columns
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4. Cross rail 5. Tool head
30. Mention any four specification of planer?
1. Maximum length of the table
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2. Total weight of the planer

3. Power of the motor
4. Range of speeds & feed available
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5. Type of drive required

31. What is meant by drilling?
Drilling is the process of producing hole on the work piece by using a rotating cutter called drill
32. What is gang - drilling machine?
When a number of single spindles with essential speed & feed are mounted side by side on one base and
have common worktable is known as gang –drilling machine.
33. Mention any four specification of drilling machine?
1. Maximum size of the drill in mm that the machine can operate
2. Table size of maximum dimensions of a job can mount on a table in square meter
3. Maximum spindle travel in mm
4. Number of spindle speed & range of spindle speeds in r.p.m.
34. List any four machining operations that can be performed on a drilling machine?
1. Drilling 3. Counter sinking
2. Tapping 4. Trepanning
35. What are the different ways to mount the drilling tool?
1. Fitting directly in the spindle
2. By using a sleeve
3. By using a socket
4. By means of chucks
36. What is broaching?
Broaching is a process of machining a surface with a special multipoint cutting tool called broach which
has successfully higher cutting edges in a fixed path.
37. Indicate any two specification of a broaching machine?
1. Maximum length of stroke in mm
2. Maximum force developed by the slide in tones
38. What are the advantages and limitation of broaching?
Advantages:
1. Roughing, semi finishing & finishing cuts are completed in one pass of the broach

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2. Broaching can be used for either external or internal surface finish
Limitation:
1. High initial cost of the broach tool compare to other tools
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2. Job work or batch work is not advisable due to the high tool cost.
39. What are the different operations that can be performed on a broaching machine?
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1. Broaching splines
2. Broaching a key way
40. What is boring?
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Boring is a process of enlarging &locating previously drilled holes with a single point cutting tool.
41. What are the application of boring?
The boring machine is designed for machining large &heavy work piece in mass production work of engine
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frame, cylinder, machine housing etc

42. Specify the importance of jig boring machine?
1. A jig boring machine is a precision boring machine used for boring accurate holes at proper center to
center distances.
2. The machining accuracy of holes produce by this machine tool lies with in a range of 0.0025mm.
43. State the purpose of grinding?
1. To remove small amount of metal from work pieces & finish then to close tolerances.
2. To obtain the better surface finish.
44. Define the term “grade” used in grinding wheel?
Grade or hardness indicates the strength with which the bonding material holds the abrasive grain in the
grinding wheel.
45. What is meant by dressing &truing?
The process of loading &breaking away the glazed surface so that new sharp abrasive particles are again
present to work for efficient cutting is called dressing.
Truing is a process of trimming the cutting surface of the wheel to run true with the axis.
46. What is process of lapping?
Lapping is a surface finishing process used for producing geometrically accurate flat, cylindrical
&spherical surface
47. What are the specifications of the milling machine?
1. The table length &width.
2. Number of spindle speeds &feeds.
3. Power of driving motor.
48. Mention the various movements of universal milling machine table?
1. Vertical movement-through the knee.
2. Cross vise movement-through the saddle.
49. State any two comparisons between plain &universal milling machine?
1. In plain milling machine the table is provided with three movements, longitudinal, cross & vertical. In
universal milling machine in addition to these three movements, there is a forth movement to the table.

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The table can be swiveled horizontally & can be fed at angles to the milling machine spindle.
2. The universal milling machine is provided with auxiliaries such as dividing head, vertical milling
attachment, rotary table etc. Hence it is possible to make spiral, bevel gears, twist drills, reamers etc on
universal milling machine.
50. What are the cutter holding devices?
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1. Arbors 2. Adaptors 3. Collets
51. List the various type of milling attachment?
1. Vertical milling 4. Universal milling
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2. High speed milling 5. Rotary

3. Slotting 6. Rack milling
52. Write any ten nomenclature of plain milling cutter?
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Body of cutter, cutting edge, face, fillet, gash, lead, land, outside dia, root dia, cutter angles.
53. What are the advantages of milling process?
1. It does not require a backlash eliminator.
2. Mild surface does not have built up edge.
54. What are the down milling processes?
1. Cutter with higher rake angle can be used. This reduces power requirements.
2. Cutter wear is less because chip thickness is maximum at the start of cut.
55. List out the various milling operations?
1. Plain or slab milling. 4. Face milling.
2. Angular milling. 5. Gang milling.
3. End milling. 6. Gear cutting.
56. What does term indexing mean?
Indexing is the process of dividing the periphery of a job into equal number of divisions.
57. What are the three types dividing heads?
1. Plain or simple.
2. Universal.
3. Optical.
58. What is cam milling?
Cam milling is operation of producing cams in the milling machine by the use universal dividing head &a
vertical milling attachment.
59. What are the different types of thread milling?
1. Thread milling by single form cutter.
2. Thread milling by multi form cutter.
60. What are the other forming methods for manufacturing gears?
1. Gear cutting by single point form tool.
2. Gear cutting by shear speed shaping process.
3. Gear broaching.

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4. Template method.
5. Gear milling using a formed end mill.
61. List the gear generating process?
1. Gear shaping process.
2. Gear planning process.
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3. Gear hobbing process.
62. Mention the applications of gear shaping process?
1. Gear shaping used for generating both internal & external spur gears.
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2. Helical gears can also be generated using special attachments.

63. What are the limitations of gear hobbing?
1. Internal gears cannot be generated.
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2. Hobbing process cannot be applied very near to shoulders.

64. What are the advantages of gear planning process?
1. Any given model can be cut using a single cutter.
2. It is a simple flexible &accurate method of generating gears.
65. List the various gear finishing processes?
1. Gear shaving. 3. Gear burnishing.
2. Gear grinding. 4. Gear lapping.
66. Mention the advantages &limitations of gear shaving process?
Advantage:
The process can be used for both internal & external gears.
Limitations:
This process is only applicable to unhardened gears.
67. What are the purposes of gear grinding process?
1. To improve the surface finish of teeth.
 2. To increase the accuracy of the teeth.
68. What is gear lapping?
Gear lapping is also employed for hardened gear teeth by an abrasive action.
69. Define Automatic lathes.
Automatic lathes or simply automats are machines tools in which all the operations required to finish off
the work piece are done automatically without the attention of an operator.
70. State any four advantages of automatic lathes.
1. Mass production of identical parts.
2. High accuracy is maintained.
3. Time of production is minimized.
4. The bar stock is fed automatically
71. What are the type’s single spindle automatic lathe?
1. Automatic cutting off machine.
2. Automatic screw cutting machine.

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3. Swiss type automatic screw machine.
72. State the purpose of providing lead cam in single automatic screw cuffing machine?
The turret slide travel is controlled by a lead cam. Cam gives a slow forward and fast return movement to
slide. ot
73. Mention the applications of single spindle automatic screw cutting machine.
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It is used for producing small jobs, screws, stepped pins, pins, bolts etc.
74. What are the advantages of a sliding head automatic lathes?
The advantage of a sliding head automatic lathe is that long, slender work pieces can be machined with
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very good surface finish, accuracy and concentricity in sliding head automatic lathes.
75. What are the four major parts of Swiss type automatic lathes?
1. Sliding headstock 3. Cam shaft
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2. Tool bracket 4. Auxiliary attachments

76. State the advantages of Swiss type screw cutting machine.
1. Wide range of speed 3. Rigid construction
2. Micrometer tool setting 4. Simple design of cams
77. State the principle of multispindle automats.
The principle of the multispindle automate is that it has a tool slide working on the jobs on all
spindles simultaneously.
78. Define cam controlled automats.
The operating mechanism for sliding, feeding are actuated by cams through levers and gears.
79. What are the purposes of using cam?
1. To control purposes in automats screw machine.
2. To control the movement of cross slide.
3. To provide uniform rate of feed to tool during machining.
4. Some time to clamp the parts.
80. How the transfer machines works?
A transfer Machine is an automatic machine. It indexes or transfers the work piece and its fixture, from
station to station while many operations are performed on it
81. State the principle of transfer machines.
A Transfer Machine is one where several machines are linked together mechanically, electrically or
hydraulically.
82. Classify transfer machines.
Transfer machines are of three basic types,
1. Inline transfer machine.
2. Drum type transfer machine.
3. Rotary indexing table transfer machine
83. What are three types of rotary systems in rotary indexing transfer machines?
 The machining heads located outside and around a circular table and operates at its periphery.
 The heads are fixed around a central column of the machine and operate the components located on

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the table below them.
 The components are carried on platens, which are fixed on a drum rotating on a horizontal axis, and
machine heads operate from the sides.
84. State the advantages of rotary transfer machines
1. A rotary transfer machine is very compact.
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2. It is used in presses for peening over rivets, nut running heads for assembling nuts to screws.
3. Electric brazing heads for assembly.
85. What are the, different machining operations performed on in-line transfer machines?
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Machining operations at each station may tapping, reaming, boring, counter boring, chamfering,
countersinking, milling and grooving.
86. How drum type transfer machine differs from rotary table?
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 The components are being transferred around a circular path to work stations. They are radically
positioned around the path at equal distances.
 The table is replaced by a drum which is mounted on trunions so that the drum rotates about a horizontal
axis.
87. What are the two types of transfer devices?
1. Rotary transfer devices
2. Hydraulic transfer devices.
88. Explain the cutting shaping process?
The required shape of metal is obtained by removing the Unwanted material from the work piece in the
form of chips is called cutting shaping. Ex: turning, drilling, milling, boring, etc
89. Mention the various parts of single point cutting tool?
1. Shank 3. Face 5. Flank
2. Cutting edge 4. Base 6. Nose
90. What is tool signature?
The various angles of tools are mentioned in a numerical number in particular order that order is known as
tool signature.
91. What is effect of back rake angle &mention the types?
Back rake angle of tool is increases the strength of cutting tool& cutting action. It can be classified in to
two types
1. Positive rake angle 2. Negative rake angle
92. What is side rake angle & mention its effects?
The angle between the tool face & the line parallel to the base of the tool. It is used to control chip flow
93. What are all the conditions for using positive rake angle?
1. To machine the work hardened materials
2. To turn the long shaft of small dia
94. When will the negative rake angles be used?
1. To machine high strength alloys

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2. The feed rates are high
95. Define orthogonal & oblique cutting?
Oblique cutting:
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The cutting edge is inclined at an acute angle with normal to the cutting velocity vector is called
oblique cutting process.
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Orthogonal cutting:
The cutting edge of tool is perpendicular to the work piece axis.
96. What is cutting force?
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The sheared material begins to flow along the cutting tool face in the form of small pieces. The compressive
force applied to form the chip is called cutting force
97. What is chip thickness ratio?
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The ratio of chip thickness before cutting to chip thickness after cutting is called chip thickness ratio.
98. What are the purposes of chip breakers?
The chip breakers are used to break the chips in to small pieces for the removal, safety & to prevent to
machine & work
99. Define Machinability of metal?
Machinability is defined as the ease with which the material can be satisfactorily machine.
100. What are the factors affecting the machinability?
1. Chemical composition of work piece material.
2. Microstructure of work piece material
101. What is machinability index?
It is the comparison of machinability different material to standard material. US material standards for
100% machinability are sae1112 hot rolled steel.
Cutting speed of metal investigated for 20 minutes tool life
𝑀𝐴𝐶𝐻𝐼𝑁𝐴𝐵𝐼𝐿𝐼𝑇𝑌 𝐼𝑁𝐷𝐸𝑋 =
Cutting speed of standard steel for 20 minutes tool life
102. How tool life is defined?
Tool life is defined as time elapsed between two consecutive tool resharpening. During this period tools
serves effectively and efficiently.
103. What are the factors affecting tool life?
1. Cutting speed 3. Feed & depth of cut
2. Tool geometry 4. Tool material
104. Express the tailor’s tool life equation?
Tailors tool life equation: VTn=C
V= Cutting speed in m/min T= Tool life in minutes
C= Constant n= Index depends upon tool & work.
105. What is the function of cutting fluids?
1. It is used to cool the cutting tool & the work piece.
2. It improves the surface finish as stated earlier.

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3. It causes the chips to break up into small parts.
4. It protects the finish surface from corrosion.
5. It prevents the corrosion of work & machine.
106. What are the properties of cutting fluid?
1. High heat absorbing capacities.
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2. It should have good lubricant properties.
3. High flash point.
4. It should be odourless.
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5. It should be non-corrosive to work & tool.

107. What are causes of wear?
The tool is subjected to three important factors such as force, temperature and sliding action due to relative
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motion between tool and the work piece. So the tool is wear easily.
 ELECTRICAL DISCHARGE MACHINING
1. Define electrical discharge machining?
EDM is the controlled erosion of electrically conductive materials by the initiation of rapid and repetitive
spark discharge between the electrode tool to the cathode and work to anode separated by a small gap kept in
the path of dielectric medium. This process also called spark erosion.
2. What are functions of dielectric fluid used in EDM?
1. It acts as an insulating medium
2. It cools the spark region and helps in keeping the tool and work piece cool.
3. It maintains a constant resistance across the gap.
4. It carries away the eroded metal particles.
3. Basic requirement of dielectric fluid used in EDM?
1. Stable Dielectric strength.
2. It should have optimum viscosity.
3. It should have high flash point.

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4. It should be chemically stable at high temperature and neutral.
5. It should not emit toxic vapours.
4. What the dielectric fluids commonly used in EDM?
1. Petroleum based hydrocarbon fluids.
2. Paraffin, white sprite, transformer oil.
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3. Kerosene, mineral oil.
4. Ethylene glycol and water miscible compounds.
5. What are the prime requirements of tool material in EDM?
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1. It should be electrically conductive.

2. It should have good machinability.
3. It should have low erosion rate.
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4. It should have low electrical resistance.

6. What is the effect of capacitance in EDM?
Increasing the capacitance causes the discharge to increase and increase both the peak current and discharge
time.
7. Name some of the tool material used in EDM?
1. Copper, brass, alloys of Zinc &tin.
2. Hardened plain carbon steel
3. Copper tungsten, silver tungsten, tungsten
4. Copper graphite and graphite.
8. What is the process parameter efficiency the MRR?
1. Energy discharge 2. Capacitance.
3. Size of work piece. 4. M/c tool design
9. Write the formula for finding the energy discharge in EDM?
W = (1/2) X EIT
 W-discharge energy I-Current
T-time E-voltage
10. How do you increase the inductance of the circuit?
A piece of iron or steel be allowed to lodge between the leads it would increase the inductance of the circuit
and reduce the M/C rate.
11. Define W/T ratio?
It is the ratio of volume of work removed to the volume of tool removed.
12. What is cycle time?
It is the sum of discharge time and waiting time.
13. Define over cut?
It is the discharge by which the machined hole in the work piece exceeds the electrode size and is
determined by both the initiating voltage and the discharge energy.
14. Define Rehardening?
While metal heated to a temperature above the critical and then rapidly cooled by the flowing dielectric

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fluid the metal is rehardened.
15. What is recast metal?
Metal heated to a temperature above the melting point and which is not displaced by the action of the spark
discharge, resoldifies as recast metal.
16. Explain electrode wear?
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A crater is produced in the electrode, which is likewise dependent on the electrode material and the energy
of the discharge.
17. What are types of power supply circuits used in EDM?
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1. R-C circuit.
2. Rotary impulse generator.
3. Controlled pulse (vacuum tube).
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4. Oscillator controlled pulse.

5. Transistor pulsed circuit.
18. What are the design factors to be considered while selecting the machine tool?
1. Number of parts to be produced. 2. Accuracy.
3. Size of work piece. 4. Size of electrode
5. Depth of cavity.
19. Why the servo controlled system is needed in EDM?
EDM requires that a constant arc gap be maintained between the electrode and the work piece to obtain
maximum machining efficiency. Therefore EDM tool in corporate some form of servo control.
20. Define wear ratio?
Wear ratio=Work piece material removed/Loss of electrode material

ELECTRO CHEMICAL MACHINING

1) Define ECM?
It is the controlled removal of metals by the anodic dissolution in an electrolytic
medium, where the work piece (anode) and the tool (cathode) are connected to the electrolytic circuit, which is kept,
immersed in the electrolytic medium.
2) Write the Faraday’s first law of electrolysis?
The amount of any material dissolved or deposited is proportional to the quantity of electrolyte passed.
3) Write the Faraday’s second law of electrolysis?
The amount of different substances dissolved or deposited by the same quantity of electricity are
proportional to their chemical equivalent weight.
4) Write Ohm’s law?
Current, I = V/R
V = Voltage (volt), R = resistance (ohm)
5) What are the factors that influence oxidation in ECM?
(i) Nature of work piece. (ii) Type of electrolyte.

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(iii) Current density. (iv) Temperature of the electrolyte.
6) What are the materials used to make the tool electrode?
Copper and copper alloys, titanium, aluminium, brass, bronze, carbon, Monel and reinforced plastic.
7) What are the main functions of electrolysis in the ECM? ot
i) For completing the electric circuit between the tool and the work piece and to allow the reaction to
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proceed efficiently.
ii) To remove the products of machining from the cutting region.
iii) To carry away the heat generated during the chemical reaction.
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iv) To avoid ion concentration at the work piece- tool gap.

8) What are the properties are expected from the electrolysis used in the ECM?
i) High thermal conductivity.
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ii) Low viscosity and high specific heat.

iii) Should chemically stable even at high temperature.
iv) Should be non-toxic and non-corrosive.
9) What are the electrolysis commonly used in ECM?
15 -20 % Nacl in water, sodium nitrate, potassium nitrate, sodium sulphate, sodium chromate and potassium
chloride.
10) What are the results which is in improper selection of electrolyte in ECM?
(i) Low machining rate. (ii) Over cut and stray cutting.
11) What are the methods generally used to filter the electrolyte?
(i) Running the system until it is contaminated completely and replaces it.
(ii) Centrifugal separation.
(iii) Sedimentation.
(iv) Use of clarifiers.
12) What are the characteristics of a good ECM tool?
 It should be a good conductor of electricity and heat.
 Easily machinable.
 Resistant to chemical reaction.
 It offers resistance to the high electrolyte pressure.
13) What are the parameters that affect the MRR?
1. Feed rate 2. Voltage
3. Concentration of the electrolyte. 4. Current density.
5. Temperature of the electrolyte 6.Velocity of the electrolyte.
14) How the current density affect the MRR?
Current density is controlled not only by the amount of current but also by the size of the gap between the
tool and the work piece. A small gap results in high current density, which in turn produce more material removal.
15) What are the advantages of ECM?
i. ECM is simple, fast and versatile method.

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ii. Surface finish can be extremely good.
iii. Fairly good tolerance can be obtained.
16) What are the limitations of ECM?
i. Large power consumption and the related problems.
ii. Sharp internal corners cannot be answered.
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iii. Maintenances of higher tolerances require complicated contours.
17) What are the applications of ECM?
ECM is used for sinking, profiling and contouring, multi hole drilling, trepanning, broaching, honing, steel
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mill applications, surfacing, sawing, contour machining of hand to hand machine materials.

ELECTO CHEMICAL GRINDING

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1. Define ECG.
ECG is the material removal process in which the material is removed by the combination of Electro-
Chemical decomposition as in ECM process and abrasive due to grinding.
2. Which material is used to make the grinding wheel?
Metal bonded diamond (or) Aluminum oxide.
3. What are the important functions of abrasive particles used in ECG?
It acts as insulator to maintain a small gap between the wheel and work piece. They are electrolysis products
from the working area. To cut chips if the wheel should contact the work piece particularly in the event of power
failure.
4. What are the advantages of ECG?
i) No thermal damage to work piece.
ii) Wheel wear is negligible.
iii) No distortion of the work piece.
5. What are the disadvantages of ECG?
High capital costs, because of the special wheel tool. Power consumption is quite high. Electrolyte is
corrosive.
6. What are the limitations of ECG?
1. The work material must be conductive.
2. Not suitable for machining soft material.
3. Require dressing tools for preparing the wheels.
7. What is the application of ECG?
1. Precision grinding of hand metals economically.
2. Grinding Carbide cutting tools inserts. 3. To grind end mill cutters more precisely.

ABRASIVE JET MACHINING

1. Define AJM?
It is the material removal process where the material is removed or machined by the impact erosion of the

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high velocity stream of air or gas and abrasive mixture, which is focused on to the work piece.
2. How does AJM differ from conventional sand blasting process?
AJM differ from the conventional sand blasting process in the way that the abrasive is much finer and
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effective control over the process parameters and cutting. Used mainly to cut hard and brittle materials, which are
thin and sensitive to heat.
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3. What are the advantages of AJM process?
1. Low capital cost
2. Less vibration.
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3. Good for difficult to reach area.

4. No heat is generated in work piece.
5. Ability to cut intricate holes of any hardness and brittleness in the material.
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6. Ability to cut fragile, brittle hard and heat sensitive material without damage
4. What are the applications of AJM?
1. For abrading and frosting glass, it is more economical than acid etching and grinding.
2. For doing hard suffuses, safe removal of smears and ceramics oxides on metals.
3. Resistive coating etc., from ports to delicate to withstand normal scrapping
4. Delicate cleaning such as removal of smudges from antique documents.
5. Machining semiconductors such as germanium etc.
5. Write the Disadvantages of AJM process?
1. Low metal removal rate.
2. Due to stay cutting accuracy is affected.
3. Parivles is imbedding in work piece.
4. Abrasive powder cannot be reused.
6. Give the formula for find the material remove rate for brittle metal?
MRR = 1.04 ( MV3/2 / ρ1/4H3/4 )
7. Give a summary of the abrasive of their application for different operation?
(1) Aluminum Cleaning, Cutting and Debar
(2) Silicon Carbide. Faster cleaning, Cutting.
(3) Glass Heads Matt polishing, cleaning
(4) Crushed glass Peening and cleaning.
8. Write the formula for find the MRR for ductile materials?
MRR = 0.5 ( MV2 / H)
9. What are the Process parameters affecting the MRR in AJM?
1. Gas Pressure. 2. Velocity of Particles. 3. Abrasive mass flow rate. 4. Mixing ratio. 5. Nozzle Tip
Distance.
10. What are the disadvantages of using abrasives again and again?
1. Cutting ability of the abrasives decreases after the large
2. Contamination of wears materials clogging the nozzle and the cutting unit orifices
11. What are the different types of nozzles heads used in AJM?

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1. Right angle head. 2. Straight head.
12. Why oxygen should not be used in AJM?
Oxygen should not be used because of fire hazard problem.
13. What are the different types abrasives used in AJM? ot
Aluminum oxides, silicon carbides, Crushed glass, Sodium bicarbonate, Dolomite
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14. Reuse of abrasives is not recommended in AJM. Why?
Reuse of abrasives is not recommended since the cutting ability of abrasive decrease after the usage and
also the contamination of wear materials clogging the nozzle and the cutting unit orifice.
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ULTRA SONIC MACHINING

1. What is ultrasonic machining?
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USM is a mechanical material removal process in which the material is removed by repetitive impact of
abrasive particles carried in liquid medium on to the work surface, by a shaped tool, vibrating at ultrasonic
frequency.
2. What are the advantages of USM?
1. High accuracy and good surface finish
2. No heat generation during machining
3. Capability of drilling circular and non-circular holes in very hard materials.
4. No thermal effects on mechanical work piece.
5. Non-conductive materials can be machined.
3. What are the Disadvantages of USM?
1. Tool wear 2. Frequent turning is required 3. Low material removal rate.
4. Not economical for soft materials. 5. Not suitable for heavy stock removal.
4. What are the applications of USM?
1. Almost all the material can be machined except some soft materials.
 2. Diamond, Tungsten, Tungsten carbide, and synthetic ruby can be successfully machined.
3. USM can be used for drilling, grinding, profiling, coining, threading and even for welding.
4. For preparing wire drawing dies and tool room items.
5. Used in jewellery for shaping jewels
6. Drilling of screw threads and curved holes in brittle materials.
5. What are the components of USM?
1. Ultrasonic transducer 2. Concentrator 3. Tool 4. Abrasive slurry
5. Abrasive feed mechanism 6. Tool feed mechanism
6. What is ultrasonic transducer?
The device used for converting any type of energy into ultrasonic wavers or vibration is called ultrasonic
transducer.
7. Write short noted on piezoelectric crystals?
Piezoelectric crystals are used foe inducing ultrasonic vibrations since they possess the capability of
changing their dimensions to the given electrical energy or in other sense they have the capability converting

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electrical energy into mechanical vibrations.
8. What is magnetostrictive effect?
It is the one in which the material changes its dimension is in response to a magnetic field.
9. What are the magnetostrivtive materials employed in USM? ot
Nickel, Iron – cobalt called as permendum, iron – aluminum called as alter.
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10. What is the purpose of concentrator used in USM?
The main purpose of the concentrator is to increase the amplitude of the vibration obtained from the
transducer.
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11. What is abrasive Slurry?

The abrasive slurry is nothing but a mixture of abrasive grains and the carrier fluid, generally water.
12. What are the different types of concentrators?
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1. Conical Type 2. Exponential type 3. Stepped type.

13. What are the characteristics of carrier fluid?
1. Good wetting characteristic 2. High thermal conductivity
3. Non-toxic and non-corrosive. 4. Should have low viscosity.
14. What are the elements of Carrier Fluid?
1. Act as a coolant. 2. Helps efficient transfer of energy.
3. Act as an acoustic bond between the work piece and the tool.
4. Act as medium to carry the abrasive machined materials and worm abrasives
15. What are the types of feed mechanisms used in USM?
1. Spring type 2. Counter – weight type
3. Motor type 4. Pneumatic and hydraulic type