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FINISHING
PROCESS
WITH MCQ
Chapter 1: Introduction to Surface Finishing

1.2 Classification of Finishing Processes

 Based on material removal:

o Mechanical (e.g., grinding, honing, lapping)
o Chemical (e.g., chemical polishing)
o Electrochemical (e.g., electropolishing)
 Based on abrasives:
o Bonded (e.g., grinding wheels)
o Loose (e.g., lapping paste)

1.3 Common Finishing Terms

 Surface Roughness (Ra): Arithmetic average of surface deviations.

 Surface Waviness: Longer wavelength deviation from flatness.
 Surface Lay: Pattern direction of tool marks.

Chapter 2: Surface Roughness and Measurement

2.1 Surface Texture Parameters

 Ra: Roughness average

 Rz: Average peak-to-valley height
 RMS: Root mean square value

2.2 Units of Measurement

 Microns (µm)
 Microinches (µin)

2.3 Surface Measurement Tools

  Stylus-type Profilometers
 Interferometers
 Optical Flats (used in lapping inspections)

2.4 Typical Surface Roughness Range for Processes

Process Surface Finish (Ra, µm)

Grinding 0.4 - 1.6
Honing 0.2 - 0.4
Lapping 0.01 - 0.1
Superfinishing 0.01 - 0.05

Chapter 3: Honing

3.1 Definition

 Honing is a finishing process used to improve the geometry and surface

finish of cylindrical bores by scrubbing an abrasive stone against the surface.

3.2 Honing Tools and Abrasives

 Honing Stones: Made from abrasive materials like Silicon Carbide,

Aluminum Oxide, CBN, or Diamond.
 Holder: Holds multiple stones which expand radially.
 Coolants: Used to flush away debris and reduce heat.

3.3 Types of Honing

 Manual Honing: Performed using hand-held tools.

 Machine Honing: Performed using a honing machine.
 Single-pass Honing: For higher productivity.
 Horizontal and Vertical Honing Machines.
3.4 Mechanism of Material Removal

 Combination of rotation and reciprocating motion.

 Produces a cross-hatch pattern ideal for lubrication retention.

3.5 Process Parameters

 Stroke Speed
 Rotation Speed
 Pressure applied by stones
 Abrasive grit size

3.6 Applications

 Engine cylinder bores

 Hydraulic cylinders
 Gear bores
 Aerospace and automobile precision components

3.7 Advantages

 High surface finish

 Improved lubrication
 Removes minimal material, thus suitable for final sizing

3.8 Limitations

 Limited to internal cylindrical surfaces

 Slower than some alternative processes

3.9 Typical Surface Finish and Accuracy

 Surface Roughness: 0.2 to 0.4 µm Ra

 Dimensional Tolerance: up to ±0.002 mm
3.10 Key RRB Exam Points

 Tool and abrasive materials

 Motion type (reciprocation + rotation)
 Pattern type (cross-hatch)
 Application areas

3.11 Sample RRB MCQs

Q1: Honing is primarily used for:
a) Flat surface finishing
b) External diameter reduction
c) Improving internal cylindrical surface finish
d) Increasing material hardness
Ans: c

Q2: Which abrasive is not commonly used in honing?

a) Silicon Carbide
b) Aluminum Oxide
c) Diamond
d) Copper
Ans: d

Chapter 4: Lapping
4.1 Definition

 Lapping is a low-speed, low-pressure finishing process where a workpiece is

rubbed against a lap charged with abrasive slurry.
 It is primarily used to produce a very fine finish and precise geometry.

4.2 Types of Lapping

 Hand Lapping: Manual operation using a flat surface and abrasive paste.
 Machine Lapping: Done on lapping machines with rotating plates.
 Single-sided and Double-sided Lapping.
4.3 Lapping Materials

 Lap: Typically made from cast iron, copper, brass, or glass.

 Abrasives: Aluminum Oxide, Silicon Carbide, Diamond.
 Carriers: Oil, water, or grease-based fluids to hold abrasives.

4.4 Mechanism of Material Removal

 Loose abrasive particles roll between the lap and the workpiece, micro-
cutting the surface.
 Results in high dimensional and geometric accuracy.
[Image Placeholder: Lapping Process Showing Lap and Workpiece Interface]

4.5 Process Characteristics

 Material Removal: Very low (measured in microns)

 Pressure: Low
 Speed: Low
 Produces flat and extremely smooth surfaces

4.6 Applications

 Optical lenses
 Valve seats
 Gauge blocks
 Mechanical seals

4.7 Advantages

 Achieves surface roughness as low as 0.01 µm

 Ideal for flatness and tight tolerance
 Suitable for hard and brittle materials

4.8 Limitations

 Low material removal rate

  Labor and time-intensive
 Not suitable for large volume production

4.9 Typical Surface Finish and Accuracy

 Surface Roughness: 0.01 to 0.1 µm Ra

 Flatness Accuracy: Up to 0.00001 mm

4.10 Key RRB Exam Points

 Loose abrasives used

 Lap material types
 Extremely fine finish and flatness
 Typical applications (gauge blocks, seals)

4.11 Sample RRB MCQs

Q1: Lapping primarily uses which type of abrasives?
a) Bonded
b) Coated
c) Loose
d) Solid
Ans: c

Q2: Which of the following is NOT a lapping application?

a) Gauge blocks
b) Internal cylindrical bores
c) Optical lenses
d) Mechanical seals
Ans: b

Chapter 5: Superfinishing

5.1 Definition
  Superfinishing is a high-precision finishing process where an abrasive stone
or stick is applied to the surface of a rotating workpiece to remove very
small amounts of material.
 The primary purpose is to produce a mirror-like surface and improve
geometrical accuracy.

5.2 How the Process is Done

 A rotating component (e.g., a shaft) is brought into contact with a set of

oscillating abrasive sticks/stones.
 The abrasive sticks oscillate with short strokes (typically <10 mm) while
maintaining contact with the rotating workpiece.
 A light pressure is applied to generate minute surface removal.
 A special coolant or lubricant is used to flush away debris and cool the
surface.

[Image Placeholder: Superfinishing process with rotating shaft and vibrating

abrasive stone]

5.3 Abrasives and Tools

 Abrasives used: Silicon Carbide, Aluminum Oxide, CBN (Cubic Boron

Nitride)
 Bonded abrasive sticks made from vitrified or resin bonds
 Fixtures designed to hold and control stone movement precisely

5.4 Process Parameters

  Oscillation frequency: 1000–2000 cycles/min
 Stroke length: 2–10 mm
 Contact pressure: Light (~0.1 to 0.2 MPa)
 Surface speed: 10–100 m/min

5.5 Applications

 Crankshafts
 Camshafts
 Precision hydraulic shafts
 Gear journals

5.6 Advantages

 Produces extremely fine surface finish (mirror-like)

 Increases bearing life
 Removes surface defects from grinding
 Enhances oil film retention

5.7 Limitations

 Only suitable for round, cylindrical surfaces

 Cannot remove large material volumes
 High equipment cost

5.8 Surface Finish and Accuracy

 Surface Roughness: 0.01–0.05 µm Ra

 Roundness tolerance: Up to 0.0005 mm

5.9 Key RRB Exam Points

 Type of motion involved (oscillation + rotation)

 Applications in crankshafts and camshafts
 Abrasives used (CBN, Al2O3, SiC)
 Process aims for final finishing after grinding
5.10 Sample RRB MCQs
Q1: Which type of motion is involved in superfinishing?
a) Only rotation
b) Rotation + reciprocation
c) Oscillation + rotation
d) Linear only
Ans: c

Q2: What is the typical surface roughness achieved in superfinishing?

a) 1–2 µm Ra
b) 0.2–0.5 µm Ra
c) 0.01–0.05 µm Ra
d) 0.1–1 µm Ra
Ans: c

6.1 Comparison Table

Feature Honing Lapping Superfinishing

Correct geometry, Extreme accuracy, fine Final finish,
Purpose
remove material finish remove defects
Bonded abrasive
Abrasive State Loose abrasive slurry Bonded stone
(stone)
Rotary + Relative motion (manual Rotary +
Motion
reciprocating or machine) oscillating
Material
Moderate Very little Very little
Removed
Surface
0.2 – 0.4 µm 0.01 – 0.1 µm 0.01 – 0.05 µm
Roughness (Ra)
Workpiece Round cylindrical
Cylindrical bores Flat or mating surfaces
Shape surfaces
Tool Feed Mechanical Manual/mechanical Spring loaded
Common Ferrous & non-
All metals, ceramics High alloy steels
Materials ferrous metals
Typical Engine cylinders, Crankshafts,
Gauges, seals, valve seats
Applications hydraulic bores camshafts
6.2 Selection Guidelines

 Use honing when:

o Internal cylindrical holes require correction.
o Moderate material removal and good surface finish are needed.
 Use lapping when:
o Flatness and tight tolerances are paramount.
o Highest finish and accuracy are required (µm level).
 Use superfinishing when:
o Surface micro-defects from grinding must be removed.
o Enhanced oil retention and fatigue resistance are needed.

6.3 Surface Finish Pattern

 Honing: Cross-hatched pattern (due to combined motions).

 Lapping: Random, uniform fine finish.
 Superfinishing: Mirror-like with unidirectional micro-grooves.

[Image Placeholder: Surface finish pattern diagrams of all three processes]

6.4 Accuracy Comparison

 Honing: Good geometrical accuracy (±0.005 mm)

 Lapping: Very high accuracy (±0.0005 mm)
 Superfinishing: Excellent roundness and finish (±0.0005 mm)

6.6 Sample RRB MCQs

Q1: Which finishing process is best for achieving the highest surface accuracy?

a) Honing b) Lapping c) Grinding d) Buffing

Ans: b

Q2: Which process uses loose abrasives in slurry form?

a) Honing b) Lapping c) Superfinishing d) Polishing

Ans: b
Q3: Honing results in which surface pattern?

a) Random finish b) Wavy pattern c) Cross-hatch pattern d) Circular swirls

Ans: c

Chapter 7: Other Finishing Processes – Buffing, Polishing, Burnishing, etc.

7.1 Buffing

 Buffing is a finishing process that uses a rotating cloth wheel (buff)

impregnated with fine abrasives to produce a high luster or mirror-like
surface.
 Typically done after polishing.

Process Steps:

 Buffing wheels are made of cotton or flannel.

 Abrasive compounds (e.g., rouge, tripoli) are applied.
  The wheel rotates at high speed and the part is pressed against it.

Applications:

 Decorative finishing of brass, aluminum, plastics.

 Automotive and cookware components.

Surface Finish:

 Very smooth, shiny finish; Ra ~ 0.05 to 0.2 µm.

RRB MCQ Tip:

 Often confused with polishing; buffing uses cloth wheels and compounds.

7.2 Polishing

 Polishing is the process of removing scratches and minor imperfections

using abrasives bonded to a flexible belt or wheel.
 Focuses on smoothing rather than material removal.

Process Steps:

 Uses abrasives like silicon carbide or aluminum oxide.

 Typically follows grinding.
 Can be manual or automatic.

Applications:

 Metal utensils, surgical tools, machine covers.

Surface Finish:

 Smoother than grinding but less glossy than buffing; Ra ~ 0.2 to 0.5 µm.

RRB MCQ Tip:

 Polishing removes scratches; buffing adds shine.

7.3 Burnishing
 A cold working process that improves surface finish and hardness without
material removal.

Process Steps:
 A hard, smooth ball or roller is pressed against the surface under high
pressure.
 Plastic deformation of peaks results in smooth surface.
Applications:

 Shafts, bearing surfaces, hydraulic pistons.

Advantages:

 Increases hardness and fatigue strength.

 No chips generated.

Surface Finish:

 Very fine finish; Ra ~ 0.05 to 0.2 µm.

RRB MCQ Tip:

 No material is removed in burnishing; surface is plastically deformed.

7.4 Electropolishing
 Electrochemical process that removes a thin layer of material using anodic
dissolution.

Process Steps:

 Workpiece made the anode in an electrolytic cell.

 Removes high points more rapidly than low points.

Applications:

 Biomedical devices, food processing equipment, aerospace components.

Advantages:

 Corrosion-resistant, bright finish, stress-free surface.

RRB MCQ Tip:

 Based on electrochemical principle; no abrasive involved.

7.5 Vibratory Finishing

 Batch process using media and vibratory motion to polish or deburr parts.

Process Steps:

 Parts and media are placed in a vibrating bowl or tub.

 Friction between parts and media polishes surfaces.

Applications:

 Deburring and cleaning of small components in bulk.

RRB MCQ Tip:

 Used for batch finishing of small parts with vibratory energy.

7.6 Comparison Table

Material Finish (Ra

Process Tool Used Motion/Mechanism
Removed µm)
Yes (very Cloth wheel +
Buffing 0.05 – 0.2 Rotary
small) compound
Abrasive
Polishing Yes 0.2 – 0.5 Rotary or linear
wheel/belt
Mechanical
Burnishing No Hard roller/ball 0.05 – 0.2
pressure
Yes
Electropolishing Electrolytic cell 0.1 – 0.4 Electrochemical
(electrochem)
Media in
Vibratory Yes 0.2 – 0.5 Vibratory motion
vibrating tub

7.7 Sample RRB MCQs Q1: Which process improves surface finish by plastic
deformation without removing material? a) Buffing b) Polishing c) Burnishing d)
Lapping Ans: c

Q2: Electropolishing is based on which principle? a) Abrasive wear b) Plastic

deformation c) Electrochemical reaction d) Impact erosion Ans: c

Q3: Buffing is typically done using which material? a) Grinding wheel b) Loose
abrasive slurry c) Cloth wheel with compound d) Lapping stone Ans: c

[To be continued... Next: Chapter 8 – Finishing Process Selection Guidelines and

RRB Question Trends]
Honing – Set 1 (25 MCQs)

Q1: Honing process primarily improves the _____ of a cylindrical bore.

a) Surface roughness
b) Geometry
c) Hardness
d) Color
Ans: b) Geometry
Explanation: Honing mainly corrects the geometry and size of internal cylindrical
holes with moderate material removal and improved surface finish.

Q2: Which type of abrasive is commonly used in honing?

a) Loose abrasive slurry
b) Bonded abrasive stone
c) Diamond paste
d) Cloth wheel compound
Ans: b) Bonded abrasive stone
Explanation: Honing uses bonded abrasive stones that cut and finish the surface
during reciprocating and rotary motion.

Q3: The typical surface roughness (Ra) achieved by honing is approximately:

a) 1.0 – 2.0 µm
b) 0.2 – 0.4 µm
c) 0.01 – 0.05 µm
d) 0.5 – 1.0 µm
Ans: b) 0.2 – 0.4 µm
Explanation: Honing generally yields a surface roughness in the range of 0.2 to
0.4 micrometers.
Q4: Which motion combination is used in honing?
a) Only rotary
b) Only reciprocating
c) Rotary + reciprocating
d) Vibratory
Ans: c) Rotary + reciprocating
Explanation: Honing employs a combined rotary and reciprocating motion to
produce a cross-hatched finish.

Q6: Which of the following materials is commonly honed?

a) Plastic sheets
b) Cylindrical metal bores
c) Ceramic tiles
d) Flat glass
Ans: b) Cylindrical metal bores
Explanation: Honing is used on cylindrical internal metal bores such as engine
cylinders.

Q7: Honing is often used after which process?

a) Grinding
b) Polishing
c) Lapping
d) Buffing
Ans: a) Grinding
Explanation: Honing is commonly a secondary finishing process after grinding to
improve geometry and finish.
Q8: The tool feed in honing is generally:
a) Manual
b) Spring loaded/mechanical
c) None
d) Vibratory
Ans: b) Spring loaded/mechanical
Explanation: Honing stones are fed mechanically or spring-loaded to maintain
contact pressure.

Q9: Honing is NOT suitable for:

a) Internal cylindrical holes
b) Flat surfaces
c) Hydraulic bores
d) Engine cylinders
Ans: b) Flat surfaces
Explanation: Honing is mostly for internal cylindrical shapes, not flat surfaces.

Q10: Which of these is a key advantage of honing?

a) High material removal rate
b) Improved bore geometry and finish
c) Color enhancement
d) Surface coating
Ans: b) Improved bore geometry and finish
Explanation: Honing improves dimensional accuracy and surface quality with
moderate material removal.

Q11: What is the main cause of abrasive action in honing?

a) Chemical reaction
b) Mechanical cutting by abrasive grains
c) Heat treatment
d) Plastic deformation
Ans: b) Mechanical cutting by abrasive grains
Explanation: Abrasive grains in the honing stone mechanically cut the surface.

Q12: Typical accuracy achievable by honing is:

a) ±0.01 mm
b) ±0.005 mm
c) ±0.1 mm
d) ±0.05 mm
Ans: b) ±0.005 mm
Explanation: Honing can achieve dimensional accuracy of around ±0.005 mm.

Q13: Honing stones are usually made of:

a) Silicon carbide or aluminum oxide
b) Diamond only
c) Steel
d) Wood
Ans: a) Silicon carbide or aluminum oxide
Explanation: Honing stones are generally bonded abrasives of silicon carbide or
aluminum oxide.

Q14: The reciprocating stroke length in honing is typically:

a) A few mm
b) Several meters
c) None
d) Centimeters to millimeters
Ans: d) Centimeters to millimeters
Explanation: Stroke length is usually small, providing a fine cross-hatch pattern.
Q15: Honing can remove:
a) Several mm of material quickly
b) Very fine amounts of material slowly
c) No material at all
d) Only surface coatings
Ans: b) Very fine amounts of material slowly
Explanation: Honing removes small amounts of material for precision finishing.

Q16: The direction of the honing tool’s rotation is:

a) Fixed direction
b) Alternates
c) Random
d) None
Ans: a) Fixed direction
Explanation: The tool rotates continuously while the workpiece reciprocates.

Q17: Honing tools are typically:

a) Large grinding wheels
b) Small abrasive stones mounted on a flexible spindle
c) Cloth wheels
d) Belt sanders
Ans: b) Small abrasive stones mounted on a flexible spindle
Explanation: Honing uses small bonded stones on a flexible shaft to follow bore
contours.

Q18: What is the typical speed range of the honing tool?

a) 10-20 rpm
b) 500-1000 rpm
c) 50-200 rpm
d) 1000-3000 rpm
Ans: c) 50-200 rpm
Explanation: Honing tools generally operate at moderate speeds around 50 to 200
rpm.

Q19: Which liquid is commonly used as a coolant/lubricant in honing?

a) Water
b) Honing oil or honing fluid
c) Gasoline
d) None
Ans: b) Honing oil or honing fluid
Explanation: Special honing fluids lubricate and carry away chips.

Q20: Honing improves which of the following in engine cylinders?

a) Thermal conductivity
b) Oil retention and sealing
c) Color and shine
d) Electrical conductivity
Ans: b) Oil retention and sealing
Explanation: The cross-hatch pattern helps retain oil for lubrication.

Q21: Honing is mostly a _____ process.

a) Rough finishing
b) Semi-finishing and finishing
c) Coating
d) Painting
Ans: b) Semi-finishing and finishing
Explanation: Honing is used after rough machining to achieve precision and
finish.
Q22: Which of the following affects the quality of honing?
a) Abrasive type
b) Honing pressure
c) Stroke length
d) All of the above
Ans: d) All of the above
Explanation: Abrasive selection, pressure, and stroke length influence honing
quality.

Q23: Which is a common defect corrected by honing?

a) Out-of-roundness
b) Surface corrosion
c) Thermal cracks
d) Paint defects
Ans: a) Out-of-roundness
Explanation: Honing can improve roundness of cylindrical holes.

Q24: Which parameter is NOT important for honing?

a) Abrasive hardness
b) Wheel rotation speed
c) Color of the stone
d) Feed rate
Ans: c) Color of the stone
Explanation: Color is cosmetic; abrasive hardness, speed, and feed are critical.

Q25: Honing is a preferred process in which industry?

a) Textile
b) Automotive and hydraulics
c) Food processing
d) Woodworking
Ans: b) Automotive and hydraulics
Explanation: Honing is widely used for engine cylinders and hydraulic
components.

Lapping – Set 2 (25 MCQs)

Q1: Lapping primarily uses which type of abrasive?

a) Bonded abrasive stones
b) Loose abrasive slurry
c) Diamond paste
d) Cloth wheel compound
Ans: b) Loose abrasive slurry
Explanation: Lapping uses loose abrasive particles suspended in a liquid (slurry)
to produce ultra-precise finishes.

Q2: The typical surface roughness (Ra) achievable by lapping is:

a) 0.2 – 0.4 µm
b) 0.01 – 0.1 µm
c) 0.1 – 0.5 µm
d) 0.5 – 1.0 µm
Ans: b) 0.01 – 0.1 µm
Explanation: Lapping achieves extremely fine finishes with surface roughness
down to a few nanometers to tenths of micrometers.

Q3: Lapping is mostly used for:

a) Internal cylindrical holes
b) Flat or mating surfaces
c) Large rough shapes
d) External cylindrical shafts
Ans: b) Flat or mating surfaces
Explanation: Lapping is ideal for flat, parallel, or mating surfaces requiring tight
tolerances.

Q4: What is the mechanism of material removal in lapping?

a) Chemical reaction
b) Plastic deformation
c) Mechanical abrasion by loose particles
d) Thermal melting
Ans: c) Mechanical abrasion by loose particles
Explanation: Loose abrasive particles in slurry cause micro-cutting and wear.

Q5: Lapping process usually requires:

a) High pressure and heat
b) A soft lap plate and abrasive slurry
c) Bonded grinding wheel
d) Chemical baths
Ans: b) A soft lap plate and abrasive slurry
Explanation: A soft lap conforms to the work surface while slurry does the
cutting.

Q6: Which abrasive is commonly used in lapping?

a) Silicon carbide or aluminum oxide
b) Only diamond
c) Wood powders
d) Steel grit
Ans: a) Silicon carbide or aluminum oxide
Explanation: Silicon carbide and aluminum oxide are common abrasives;
diamond is used for very hard materials.
Q7: Lapping is NOT suitable for:
a) Ultra-fine finishes
b) Hard brittle materials
c) Rough shaping
d) Flat surfaces
Ans: c) Rough shaping
Explanation: Lapping is a finishing process; rough shaping is done by grinding or
machining.

Q8: Which motion is involved in lapping?

a) Only rotary
b) Relative motion between work and lap plate
c) Reciprocating only
d) Vibratory only
Ans: b) Relative motion between work and lap plate
Explanation: Workpiece and lap plate move relative to each other in various
directions.

Q9: Typical accuracy achievable by lapping is:

a) ±0.01 mm
b) ±0.005 mm
c) ±0.0005 mm
d) ±0.05 mm
Ans: c) ±0.0005 mm
Explanation: Lapping can achieve very high precision tolerances.

Q10: Which surface finish pattern is typical in lapping?

a) Cross-hatched
b) Random, uniform fine finish
c) Parallel grooves
d) Circular swirls
Ans: b) Random, uniform fine finish
Explanation: Loose abrasives create random fine scratches evenly over surface.

Q11: Lapping is often used to finish:

a) Engine cylinders
b) Gauge blocks and valve seats
c) Wooden furniture
d) Rubber seals
Ans: b) Gauge blocks and valve seats
Explanation: Lapping produces ultra-flat, smooth surfaces for precise instruments.

Q12: What is the role of the lap plate?

a) To hold bonded abrasives
b) To apply abrasive slurry and conform to workpiece shape
c) To cool the workpiece
d) To polish chemically
Ans: b) To apply abrasive slurry and conform to workpiece shape
Explanation: Lap plate holds slurry and conforms to the workpiece for uniform
abrasion.

Q13: Lapping slurry can be:

a) Dry abrasive powder only
b) Abrasive particles suspended in a liquid
c) Abrasive paste only
d) None of the above
Ans: b) Abrasive particles suspended in a liquid
Explanation: Slurry contains abrasive particles dispersed in oil or water.
Q14: Which is a disadvantage of lapping?
a) High material removal rate
b) Slow process
c) Poor surface finish
d) Limited accuracy
Ans: b) Slow process
Explanation: Lapping is slow due to fine abrasive action and precision required.

Q15: Which process generally precedes lapping?

a) Grinding or machining
b) Polishing
c) Buffing
d) Honing
Ans: a) Grinding or machining
Explanation: Rough shaping is done before lapping for final finishing.

Q16: Lapping is most effective for materials that are:

a) Soft and ductile
b) Hard and brittle
c) Plastic and flexible
d) Porous and spongy
Ans: b) Hard and brittle
Explanation: Lapping suits hard, brittle materials needing ultra-smooth surfaces.

Q17: Lapping can be done:

a) Manually
b) Mechanically or manually
c) Only mechanically
d) Only chemically
Ans: b) Mechanically or manually
Explanation: Both manual and machine lapping are used depending on
application.

Q18: Which is true about the pressure applied in lapping?

a) Very high pressure needed
b) Low to moderate pressure preferred
c) No pressure applied
d) Pressure varies randomly
Ans: b) Low to moderate pressure preferred
Explanation: Excess pressure can embed abrasive or damage surface.

Q19: Lapping is often used for producing:

a) Decorative coatings
b) Optical flats and precision instruments
c) Rough castings
d) Painted surfaces
Ans: b) Optical flats and precision instruments
Explanation: Lapping produces extremely flat, smooth surfaces used in optics.

Q20: Which is NOT a typical abrasive in lapping slurry?

a) Aluminum oxide
b) Silicon carbide
c) Wood powder
d) Diamond
Ans: c) Wood powder
Explanation: Wood powder is not used as an abrasive in lapping.
Q21: The surface produced by lapping is generally:
a) Mirror-like and free of defects
b) Rough and irregular
c) Covered in scratches and pits
d) Matte and dull
Ans: a) Mirror-like and free of defects
Explanation: Lapping produces extremely smooth and defect-free surfaces.

Q22: Which of the following affects lapping performance?

a) Lap plate hardness
b) Abrasive size
c) Slurry concentration
d) All of the above
Ans: d) All of the above
Explanation: These parameters influence material removal rate and finish quality.

Q23: Lapping is mainly a:

a) Finishing process
b) Rough machining process
c) Heat treatment process
d) Coating process
Ans: a) Finishing process
Explanation: Lapping is used for final surface finishing and precision tolerance.

Q24: What happens if the slurry is too coarse in lapping?

a) Faster material removal but rougher surface
b) Slower removal and finer finish
c) No effect
d) Surface polishing improves
Ans: a) Faster material removal but rougher surface
Explanation: Coarser slurry removes material faster but reduces finish quality.

Q25: The lap plate material is usually:

a) Steel
b) Cast iron, copper, or pitch
c) Plastic
d) Wood
Ans: b) Cast iron, copper, or pitch
Explanation: These materials provide suitable conformity and abrasive holding.

Superfinishing – Set 3 (25 MCQs)

Q1: Superfinishing typically uses which type of abrasive?

a) Loose abrasive slurry
b) Bonded abrasive stones
c) Polishing compound
d) Grinding wheel
Ans: b) Bonded abrasive stones
Explanation: Superfinishing employs fine bonded abrasive stones to achieve
mirror-like finishes.

Q2: The primary motion in superfinishing is:

a) Rotary + oscillating
b) Reciprocating only
c) Vibratory only
d) Rotary only
Ans: a) Rotary + oscillating
Explanation: Combined rotary and oscillatory motion produces uniform micro-
finish.
Q3: Surface roughness (Ra) after superfinishing typically is:
a) 0.2 – 0.4 µm
b) 0.01 – 0.05 µm
c) 0.1 – 0.5 µm
d) 0.5 – 1.0 µm
Ans: b) 0.01 – 0.05 µm
Explanation: Superfinishing gives extremely smooth surfaces better than grinding
or honing.

Q4: Superfinishing is mainly used to:

a) Remove large amounts of material
b) Remove grinding-induced micro-defects
c) Shape rough surfaces
d) Apply coatings
Ans: b) Remove grinding-induced micro-defects
Explanation: It improves fatigue life by removing small surface irregularities.

Q5: Which is a common abrasive used in superfinishing stones?

a) Aluminum oxide
b) Silicon carbide
c) Diamond
d) All of the above
Ans: d) All of the above
Explanation: Abrasive choice depends on material being finished.

Q6: Typical feed pressure in superfinishing is:

a) Very high
b) Low (0.1 to 0.4 MPa)
c) Zero
d) Varies widely
Ans: b) Low (0.1 to 0.4 MPa)
Explanation: Low pressure prevents damage and ensures fine finish.

Q7: The workpiece surface after superfinishing exhibits:

a) Cross-hatch pattern
b) Random scratches
c) Unidirectional micro-grooves
d) No pattern
Ans: c) Unidirectional micro-grooves
Explanation: Oscillating stones produce fine, uniform grooves aiding lubrication.

Q8: Superfinishing is mainly applied to:

a) Flat surfaces
b) Cylindrical surfaces like shafts and bores
c) Rough castings
d) Plastic parts
Ans: b) Cylindrical surfaces like shafts and bores
Explanation: It is effective for round parts needing high fatigue resistance.

Q9: Which is a benefit of superfinishing?

a) High material removal rate
b) Improved fatigue life and wear resistance
c) Large dimensional corrections
d) Surface coating
Ans: b) Improved fatigue life and wear resistance
Explanation: Micro-smooth surfaces reduce stress concentrations.
Q10: Superfinishing stones are typically:
a) Large and rough
b) Small and fine
c) Very hard and coarse
d) Made of plastic
Ans: b) Small and fine
Explanation: Stones are fine and small to produce smooth finishes with low
pressure.

Q11: Which motion is NOT typical in superfinishing?

a) Rotary
b) Oscillating
c) Reciprocating
d) Vibratory
Ans: d) Vibratory
Explanation: Vibratory motion is not generally used in superfinishing.

Q12: The feed rate in superfinishing is:

a) High speed
b) Low speed
c) Zero
d) Random
Ans: b) Low speed
Explanation: Low speed ensures controlled, precise finishing.

Q13: Superfinishing is usually done after:

a) Rough machining
b) Grinding
c) Polishing
d) Lapping
Ans: b) Grinding
Explanation: It removes grinding defects and improves surface finish.

Q14: Typical tolerance achievable in superfinishing is:

a) ±0.005 mm
b) ±0.0005 mm
c) ±0.05 mm
d) ±0.1 mm
Ans: b) ±0.0005 mm
Explanation: Superfinishing achieves excellent dimensional accuracy.

Q15: Superfinishing stones are generally made from:

a) Ceramic bonded abrasives
b) Metal bonded abrasives
c) Resin bonded abrasives
d) Any of the above
Ans: d) Any of the above
Explanation: Choice depends on application and material.

Q16: Superfinishing improves surface by:

a) Creating deep scratches
b) Removing only surface coating
c) Removing microscopic surface irregularities
d) Applying a surface coating
Ans: c) Removing microscopic surface irregularities
Explanation: This enhances performance and longevity.

Q17: The process of superfinishing can also be called:

a) Fine grinding
b) Microfinishing
c) Rough machining
d) Buffing
Ans: b) Microfinishing
Explanation: It is a precise finishing process producing very fine surface.

Q18: Which is NOT an application of superfinishing?

a) Crankshafts
b) Camshafts
c) Engine cylinder bores
d) Wood furniture
Ans: d) Wood furniture
Explanation: Wood finishing does not use superfinishing.

Q19: Which factor does NOT affect superfinishing?

a) Abrasive type
b) Stone speed
c) Feed pressure
d) Workpiece color
Ans: d) Workpiece color
Explanation: Color does not influence finishing quality.

Q20: Which surface finish value indicates superfinishing?

a) 0.3 µm Ra
b) 0.05 µm Ra
c) 1.0 µm Ra
d) 0.5 µm Ra
Ans: b) 0.05 µm Ra
Explanation: Superfinishing achieves Ra typically below 0.05 µm.
Q21: Superfinishing stones are usually:
a) Large flat discs
b) Small rectangular bars
c) Thin wires
d) Powder form
Ans: b) Small rectangular bars
Explanation: Bars or sticks are used to finish cylindrical surfaces.

Q22: Superfinishing stones remove material by:

a) Chemical erosion
b) Microabrasion
c) Melting
d) Electrical discharge
Ans: b) Microabrasion
Explanation: Fine abrasive action removes microscopic irregularities.

Q23: Surface microstructure after superfinishing is:

a) Rough and jagged
b) Smooth with uniform microgrooves
c) Covered with burrs
d) Dented and cracked
Ans: b) Smooth with uniform microgrooves
Explanation: Microgrooves improve lubrication and reduce wear.

Q24: Superfinishing is important in parts subjected to:

a) High stress and fatigue
b) Low stress
c) Static load only
d) No mechanical load
Ans: a) High stress and fatigue
Explanation: Smooth surfaces reduce crack initiation.

Q25: Superfinishing reduces:

a) Material hardness
b) Surface tensile stress
c) Surface friction and wear
d) Size of the component
Ans: c) Surface friction and wear
Explanation: Smooth finish reduces friction leading to less wear.

Buffing, Polishing, Burnishing and Other Finishing Processes – Set 4 (25

MCQs)

Q1: Buffing is mainly used to:

a) Remove large amounts of material
b) Produce a high-gloss surface finish
c) Correct dimensional errors
d) Hardening the surface
Ans: b) Produce a high-gloss surface finish
Explanation: Buffing removes fine scratches and imparts shine.

Q2: Polishing is different from buffing because:

a) Polishing uses abrasive compounds
b) Buffing uses loose abrasives
c) Polishing removes more material
d) Polishing is slower than buffing
Ans: a) Polishing uses abrasive compounds
Explanation: Polishing uses abrasive powders or pastes; buffing uses loose
abrasives on cloth wheels.

Q3: Burnishing improves surface finish by:

a) Removing material
b) Plastic deformation of surface peaks
c) Chemical etching
d) Applying coatings
Ans: b) Plastic deformation of surface peaks
Explanation: Burnishing smooths surface by cold working peaks into valleys.

Q4: Which process uses a rotating wheel covered with cloth?

a) Lapping
b) Buffing
c) Honing
d) Grinding
Ans: b) Buffing
Explanation: Buffing wheels are typically cloth-covered.

Q5: Polishing compounds are usually made of:

a) Diamond powder
b) Rouge or tripoli
c) Aluminum oxide slurry
d) Silicon carbide
Ans: b) Rouge or tripoli
Explanation: These are common polishing abrasives.

Q6: Burnishing is typically done on:

a) Soft materials
b) Hard materials
c) Ceramics only
d) Plastics only
Ans: a) Soft materials
Explanation: Burnishing causes plastic deformation; soft metals respond better.

Q7: Buffing and polishing are usually used to achieve:

a) High dimensional accuracy
b) Cosmetic surface finish
c) Large material removal
d) Improve hardness
Ans: b) Cosmetic surface finish
Explanation: Both improve appearance, not geometry.

Q8: Which finishing process does not remove material?

a) Lapping
b) Honing
c) Burnishing
d) Grinding
Ans: c) Burnishing
Explanation: Burnishing plastically deforms surface without removing material.

Q9: Which process uses a rotating tool with abrasive slurry?

a) Honing
b) Polishing
c) Lapping
d) Buffing
Ans: c) Lapping
Explanation: Lapping uses loose abrasive slurry between surfaces.
Q10: Typical surface roughness after polishing is:
a) 1 – 2 µm Ra
b) 0.1 – 0.5 µm Ra
c) 0.01 – 0.05 µm Ra
d) 0.5 – 1.0 µm Ra
Ans: b) 0.1 – 0.5 µm Ra
Explanation: Polishing gives smooth surfaces but not as smooth as superfinishing.

Q11: Burnishing tools are usually made of:

a) Soft rubber
b) Hardened steel or carbide
c) Plastic
d) Wood
Ans: b) Hardened steel or carbide
Explanation: To apply sufficient pressure and cause plastic deformation.

Q12: Buffing wheels rotate at:

a) 500 – 1000 RPM
b) 1000 – 3000 RPM
c) 3000 – 6000 RPM
d) Less than 500 RPM
Ans: b) 1000 – 3000 RPM
Explanation: This speed range is typical for polishing and buffing.

Q13: Which process uses chemicals to remove surface irregularities?

a) Electro-polishing
b) Buffing
c) Lapping
d) Burnishing
Ans: a) Electro-polishing
Explanation: Electro-polishing dissolves metal ions selectively.

Q14: Polishing is often followed by:

a) Grinding
b) Buffing
c) Lapping
d) Honing
Ans: b) Buffing
Explanation: Buffing gives the final glossy finish.

Q15: In burnishing, the surface hardness typically:

a) Increases
b) Decreases
c) Remains same
d) Varies randomly
Ans: a) Increases
Explanation: Cold working increases surface hardness (work hardening).

Q16: Buffing compounds come in:

a) Liquid form
b) Solid paste or powder
c) Gas
d) Wire form
Ans: b) Solid paste or powder
Explanation: These compounds are applied on buffing wheels.
Q17: Polishing removes material by:
a) Chemical reaction
b) Mechanical abrasion
c) Heat treatment
d) Plastic deformation
Ans: b) Mechanical abrasion
Explanation: Polishing uses abrasive particles to remove surface irregularities.

Q18: The main purpose of buffing is to:

a) Achieve dimensional accuracy
b) Enhance surface appearance and luster
c) Correct shape errors
d) Improve material strength
Ans: b) Enhance surface appearance and luster
Explanation: Buffing is cosmetic finishing.

Q19: Burnishing is commonly used on:

a) Engine parts
b) Plastic components
c) Wood surfaces
d) Glass surfaces
Ans: a) Engine parts
Explanation: To improve surface finish and fatigue strength.

Q20: Which finishing process produces a mirror-like finish?

a) Buffing
b) Lapping
c) Burnishing
d) Grinding
Ans: a) Buffing
Explanation: Buffing produces high-gloss mirror finish.

Q21: Which process is best for flat surfaces?

a) Honing
b) Lapping
c) Superfinishing
d) Burnishing
Ans: b) Lapping
Explanation: Lapping achieves high accuracy on flat surfaces.

Q22: The abrasive size in polishing is typically:

a) Coarse (100-200 mesh)
b) Medium (400-600 mesh)
c) Fine (600-1200 mesh)
d) Very coarse (below 50 mesh)
Ans: c) Fine (600-1200 mesh)
Explanation: Fine abrasives are used to achieve smooth surfaces.

Q23: Buffing is NOT suitable for:

a) Soft metals
b) Hard metals
c) Plastics
d) Rough machining
Ans: d) Rough machining
Explanation: Buffing is a finishing, not a machining process.

Q24: Polishing generally improves:

a) Corrosion resistance
b) Thermal conductivity
c) Magnetic properties
d) Electrical resistance
Ans: a) Corrosion resistance
Explanation: Smooth surfaces reduce corrosion sites.

Q25: Which process involves plastic deformation without material removal?

a) Honing
b) Burnishing
c) Lapping
d) Superfinishing
Ans: b) Burnishing
Explanation: Burnishing smooths surface by deformation, not abrasion.

Grinding Processes – Set 5 (25 MCQs)

Q1: What is the primary purpose of grinding?

a) Material removal with high precision
b) Surface coating
c) Welding
d) Casting
Ans: a) Material removal with high precision
Explanation: Grinding is mainly used to achieve precise dimensions and surface
finish by removing small amounts of material.

Q2: The abrasive material commonly used in grinding wheels is:

a) Silicon carbide
b) Diamond
c) Aluminum oxide
d) Both b and c
Ans: d) Both b and c
Explanation: Aluminum oxide is used for steel grinding; diamond is used for hard
materials.

Q3: The surface speed of a grinding wheel is typically measured in:

a) RPM
b) m/s
c) m/min
d) Rad/s
Ans: c) m/min
Explanation: Grinding wheel surface speed is given in meters per minute (m/min).

Q4: Which grinding process is used to finish internal cylindrical surfaces?

a) Surface grinding
b) Cylindrical grinding
c) Internal grinding
d) Centerless grinding
Ans: c) Internal grinding
Explanation: Internal grinding is used for bores and holes.

Q5: The typical grain size for rough grinding wheels is:
a) 10-20 mesh
b) 60-80 mesh
c) 120-150 mesh
d) 200-300 mesh
Ans: b) 60-80 mesh
Explanation: Coarser grains are used for rough grinding.
Q6: In centerless grinding, the workpiece is supported by:
a) Centers
b) A work rest blade
c) Chuck
d) Magnetic chuck
Ans: b) A work rest blade
Explanation: The workpiece rests on a blade and is supported between grinding
and regulating wheels.

Q7: Which parameter directly affects the surface finish in grinding?

a) Wheel speed
b) Feed rate
c) Depth of cut
d) All of the above
Ans: d) All of the above
Explanation: All these factors influence the grinding quality.

Q8: What is the role of coolant in grinding?

a) Increase grinding wheel speed
b) Remove chips and cool workpiece
c) Harden the grinding wheel
d) Improve abrasive grain size
Ans: b) Remove chips and cool workpiece
Explanation: Coolants reduce heat and flush away chips.

Q9: The process of restoring the sharpness of a grinding wheel is called:

a) Truing
b) Dressing
c) Balancing
d) Conditioning
Ans: b) Dressing
Explanation: Dressing removes loaded material and exposes fresh grains.

Q10: Truing a grinding wheel means:

a) Sharpening the abrasive grains
b) Making the wheel round and concentric
c) Cooling the wheel
d) Cleaning the wheel
Ans: b) Making the wheel round and concentric
Explanation: Truing ensures correct shape and concentricity.

Q11: Which grinding process does NOT use a workpiece held between centers?
a) Cylindrical grinding
b) Internal grinding
c) Centerless grinding
d) Surface grinding
Ans: c) Centerless grinding
Explanation: Centerless grinding supports workpiece without centers.

Q12: Which abrasive is used for grinding hard materials like ceramics?
a) Aluminum oxide
b) Silicon carbide
c) Diamond
d) Emery
Ans: c) Diamond
Explanation: Diamond abrasives are best for very hard materials.

Q13: Typical grinding wheel speed ranges from:

a) 100 – 500 m/min
b) 10 – 50 m/min
c) 2000 – 3000 m/min
d) 50 – 100 m/min
Ans: a) 100 – 500 m/min
Explanation: This is a typical operational speed range.

Q14: The term "grit" in grinding wheels refers to:

a) Bond type
b) Abrasive grain size
c) Wheel diameter
d) Wheel hardness
Ans: b) Abrasive grain size
Explanation: Grit size indicates the size of abrasive particles.

Q15: Which grinding process is best for flat surfaces?

a) Surface grinding
b) Cylindrical grinding
c) Centerless grinding
d) Internal grinding
Ans: a) Surface grinding
Explanation: Surface grinding produces flat surfaces.

Q16: Which grinding operation is used to remove defects after heat treatment?
a) Superfinishing
b) Honing
c) Grinding
d) Lapping
Ans: c) Grinding
Explanation: Grinding removes scale and corrects shape after heat treatment.
Q17: Wheel wear in grinding causes:
a) Wheel diameter to increase
b) Poor surface finish
c) Increased cutting forces
d) All of the above
Ans: c) Increased cutting forces
Explanation: Wheel wear reduces sharpness, increasing forces.

Q18: Which grinding process uses a reciprocating motion?

a) Surface grinding
b) Cylindrical grinding
c) Internal grinding
d) All of the above
Ans: a) Surface grinding
Explanation: Surface grinders often have reciprocating table motion.

Q19: The bond in grinding wheels holds:

a) Abrasive grains together
b) Coolant in place
c) Workpiece steady
d) Wheel on spindle
Ans: a) Abrasive grains together
Explanation: Bond material holds abrasive grains in the wheel.

Q20: Typical materials for grinding wheels’ bond are:

a) Vitrified, resin, metal
b) Rubber, plastic, wood
c) Ceramic, glass, sand
d) Steel, aluminum, copper
Ans: a) Vitrified, resin, metal
Explanation: These bonds provide strength and wear resistance.

Q21: In internal grinding, the grinding wheel:

a) Is larger than the workpiece bore
b) Is smaller than the workpiece bore
c) Is same size as bore
d) Is not used
Ans: b) Is smaller than the workpiece bore
Explanation: Smaller wheel fits inside the bore to grind internal surfaces.

Q22: The main advantage of centerless grinding is:

a) High production rate
b) Very fine finish
c) Ability to grind very small parts
d) Low cost of tooling
Ans: a) High production rate
Explanation: Centerless grinding can process many parts continuously.

Q23: Which is a common problem in grinding that causes thermal damage?

a) Wheel glazing
b) Wheel loading
c) Wheel burning
d) Wheel dressing
Ans: c) Wheel burning
Explanation: Excess heat causes surface burns or cracks on workpiece.

Q24: What does wheel “hardness” indicate?

a) Abrasive grain size
b) Resistance to wear and grain retention
c) Diameter of wheel
d) Speed of wheel
Ans: b) Resistance to wear and grain retention
Explanation: Hardness rating shows how tightly grains are held.

Q25: The typical depth of cut in grinding is:

a) 0.1 – 0.5 mm
b) 5 – 10 mm
c) 10 – 20 mm
d) 1 – 2 mm
Ans: a) 0.1 – 0.5 mm
Explanation: Grinding removes small amounts of material per pass.

Polishing, Buffing & Burnishing – Set 7 (25 MCQs)

Q1: Polishing primarily aims to:

a) Remove large amounts of material
b) Improve surface finish and shine
c) Correct dimensional errors
d) Harden the surface
Ans: b) Improve surface finish and shine
Explanation: Polishing enhances surface smoothness and imparts a bright finish.

Q2: The abrasive used in polishing is generally:

a) Loose abrasive slurry
b) Fine abrasive paste or powder
c) Coarse grinding grains
d) Diamond stones
Ans: b) Fine abrasive paste or powder
Explanation: Polishing uses fine abrasives for smooth finishes.

Q3: Buffing differs from polishing because it:

a) Uses softer wheels and produces a higher luster
b) Removes more material
c) Is used for rough surfaces
d) Uses coarser abrasives
Ans: a) Uses softer wheels and produces a higher luster
Explanation: Buffing uses soft cloth wheels and compounds for a mirror-like
finish.

Q4: The wheels used in buffing are generally made of:

a) Steel
b) Cloth or felt
c) Diamond
d) Resin
Ans: b) Cloth or felt
Explanation: Soft wheels allow polishing compounds to create high shine.

Q5: Burnishing improves surface finish by:

a) Removing surface material
b) Plastic deformation of surface peaks
c) Applying abrasive slurry
d) Heating the surface
Ans: b) Plastic deformation of surface peaks
Explanation: Burnishing smooths surface by cold working the surface peaks.
Q6: Which of these is NOT a finishing process?
a) Polishing
b) Buffing
c) Grinding
d) Burnishing
Ans: c) Grinding
Explanation: Grinding is a material removal process; others are finishing.

Q7: Which finishing process is typically used on metals to improve wear

resistance?
a) Polishing
b) Buffing
c) Burnishing
d) Lapping
Ans: c) Burnishing
Explanation: Burnishing cold-works the surface to improve hardness and wear.

Q8: Polishing and buffing are usually done:

a) Before grinding
b) After grinding or machining
c) Before heat treatment
d) During casting
Ans: b) After grinding or machining
Explanation: These are final finishing steps after shaping.

Q9: Which finishing process imparts a mirror-like finish?

a) Polishing
b) Buffing
c) Both a and b
d) Burnishing
Ans: c) Both a and b
Explanation: Both polishing and buffing produce shiny surfaces.

Q10: Which abrasive is commonly used in polishing metal surfaces?

a) Alumina (Aluminum oxide)
b) Emery
c) Tripoli
d) All of the above
Ans: d) All of the above
Explanation: Different abrasives are used depending on material and finish.

Q11: The main difference between polishing and buffing is:

a) Polishing uses rough abrasives; buffing uses fine abrasives
b) Polishing removes material; buffing smooths surface
c) Buffing uses soft wheels and polishing uses hard wheels
d) Polishing is dry; buffing uses liquid
Ans: c) Buffing uses soft wheels and polishing uses hard wheels
Explanation: Buffing uses soft cloth wheels for finer finish.

Q12: Which finishing process uses pressure and hard tools to improve surface
hardness?
a) Grinding
b) Burnishing
c) Lapping
d) Honing
Ans: b) Burnishing
Explanation: Burnishing plastically deforms surface peaks to harden.
Q13: Polishing compound is usually:
a) Water-based
b) Oil-based
c) Paste or powder applied to the wheel
d) None of the above
Ans: c) Paste or powder applied to the wheel
Explanation: Compounds help abrasives cut finer and produce shine.

Q14: Buffing wheels are typically:

a) Made of rubber
b) Made of cotton or wool
c) Made of steel
d) Made of plastic
Ans: b) Made of cotton or wool
Explanation: Soft fibers produce high polish and finish.

Q15: Burnishing is mostly done:

a) On soft metals
b) On hard metals
c) On plastics
d) On ceramics
Ans: a) On soft metals
Explanation: Soft metals respond better to plastic deformation from burnishing.

Q16: The advantage of buffing over polishing is:

a) Faster material removal
b) Better surface finish with less material removal
c) Lower cost
d) Uses coarser abrasives
Ans: b) Better surface finish with less material removal
Explanation: Buffing produces a high gloss with minimal material removal.

Q17: Which finishing process is used for decorative purposes and corrosion
resistance?
a) Polishing
b) Buffing
c) Both
d) Burnishing
Ans: c) Both
Explanation: Both improve surface aesthetics and corrosion resistance.

Q18: Burnishing tools are generally made of:

a) Hardened steel
b) Rubber
c) Wood
d) Soft metals
Ans: a) Hardened steel
Explanation: Hard tools plastically deform metal surfaces during burnishing.

Q19: Which process can cause work hardening of the surface?

a) Polishing
b) Buffing
c) Burnishing
d) Lapping
Ans: c) Burnishing
Explanation: Plastic deformation causes strain hardening.
Q20: The sequence of finishing from rough to fine is:
a) Grinding → Polishing → Buffing → Burnishing
b) Polishing → Buffing → Grinding → Burnishing
c) Burnishing → Grinding → Polishing → Buffing
d) Buffing → Grinding → Polishing → Burnishing
Ans: a) Grinding → Polishing → Buffing → Burnishing
Explanation: Grinding removes rough material; polishing and buffing refine
finish; burnishing improves hardness.

Q21: Which process generally produces the lowest surface roughness (Ra)?
a) Polishing
b) Buffing
c) Burnishing
d) Lapping
Ans: d) Lapping
Explanation: Lapping produces extremely fine finishes with Ra down to a few
nanometers.

Q22: Which abrasive compound is often used in buffing for metal finishing?
a) Rouge
b) Tripoli
c) Emery
d) Silicon carbide
Ans: a) Rouge
Explanation: Rouge is a fine abrasive compound for polishing metals.

Q23: Which process uses a rotating tool with pressure applied to the work surface?
a) Buffing
b) Burnishing
c) Polishing
d) Lapping
Ans: b) Burnishing
Explanation: Burnishing applies pressure via a rotating hard tool.

Q24: Polishing and buffing are mostly:

a) Dry processes
b) Wet processes using water or oil-based compounds
c) Performed only manually
d) Not used in industry
Ans: b) Wet processes using water or oil-based compounds
Explanation: Compounds require lubrication to reduce heat and friction.

Q25: Which process can help improve the fatigue strength of a metal surface?
a) Polishing
b) Buffing
c) Burnishing
d) Grinding
Ans: c) Burnishing
Explanation: Burnishing induces compressive residual stress improving fatigue
life.

Thermal & Chemical Finishing Processes – Set 8 (25 MCQs)

Q1: Electroplating is primarily used to:

a) Clean metal surfaces
b) Deposit a thin metal layer on a substrate
c) Harden the surface by heating
d) Remove rust from metals
Ans: b) Deposit a thin metal layer on a substrate
Explanation: Electroplating deposits metals like nickel, chromium onto parts for
protection and aesthetics.

Q2: In electroplating, the workpiece acts as:

a) Anode
b) Cathode
c) Electrolyte
d) None
Ans: b) Cathode
Explanation: Metal ions deposit on the cathode (workpiece).

Q3: Anodizing is mainly applied to:

a) Steel
b) Aluminum
c) Copper
d) Titanium
Ans: b) Aluminum
Explanation: Anodizing forms a protective oxide layer on aluminum.

Q4: Which of the following is a heat treatment process?

a) Painting
b) Annealing
c) Electroplating
d) Polishing
Ans: b) Annealing
Explanation: Annealing softens metals by controlled heating and cooling.

Q5: The main purpose of painting as a finishing process is:

a) Increase mechanical strength
b) Corrosion protection and aesthetics
c) Surface hardening
d) Lubrication
Ans: b) Corrosion protection and aesthetics
Explanation: Paint protects from corrosion and improves appearance.

Q6: Which heat treatment involves rapid cooling?

a) Annealing
b) Normalizing
c) Quenching
d) Tempering
Ans: c) Quenching
Explanation: Quenching rapidly cools metal to increase hardness.

Q7: Electroplating requires an electrolyte solution containing:

a) Metal ions of the plating metal
b) Acidic water only
c) Neutral salt solution
d) Organic solvent
Ans: a) Metal ions of the plating metal
Explanation: Electrolyte supplies metal ions to be deposited.

Q8: Tempering is done to:

a) Increase hardness
b) Increase toughness and reduce brittleness
c) Remove oxide layers
d) Polish the surface
Ans: b) Increase toughness and reduce brittleness
Explanation: Tempering improves ductility after quenching.
Q9: Which of these finishes improves electrical insulation?
a) Electroplating
b) Anodizing
c) Burnishing
d) Polishing
Ans: b) Anodizing
Explanation: Anodized aluminum oxide is an electrical insulator.

Q10: Paints generally consist of:

a) Pigment, binder, solvent
b) Abrasive, water, oil
c) Metal powder, resin, acid
d) Solvent, metal ions, electrolytes
Ans: a) Pigment, binder, solvent
Explanation: These components form paint and adhere it to surfaces.

Q11: Pickling in chemical finishing is used to:

a) Deposit a protective layer
b) Remove scale and oxides
c) Harden the surface
d) Add color
Ans: b) Remove scale and oxides
Explanation: Pickling uses acids to clean metal surfaces.

Q12: The primary purpose of normalizing is to:

a) Harden steel
b) Refine grain structure and relieve stresses
c) Coat the surface
d) Remove surface rust
Ans: b) Refine grain structure and relieve stresses
Explanation: Normalizing heats steel above critical temp and air cools it.

Q13: The thickness of anodized layer on aluminum is typically:

a) 5-10 microns
b) 0.1-1 micron
c) 50-100 microns
d) 1-5 mm
Ans: a) 5-10 microns
Explanation: Anodized layers are thin but hard and protective.

Q14: Galvanizing is a process of:

a) Electroplating copper
b) Coating steel with zinc
c) Heat treating iron
d) Painting steel
Ans: b) Coating steel with zinc
Explanation: Galvanizing protects steel from corrosion by zinc coating.

Q15: Which heat treatment process removes internal stresses?

a) Annealing
b) Quenching
c) Case hardening
d) Nitriding
Ans: a) Annealing
Explanation: Annealing relieves stresses by slow cooling.

Q16: The electrolyte used in anodizing is typically:

a) Acidic (sulfuric acid) solution
b) Alkaline solution
c) Neutral water
d) Organic solvent
Ans: a) Acidic (sulfuric acid) solution
Explanation: Acid electrolyte helps form oxide layers on aluminum.

Q17: Heat treatment that involves heating surface to high temperature and cooling
fast to harden only the surface is called:
a) Annealing
b) Normalizing
c) Case hardening
d) Tempering
Ans: c) Case hardening
Explanation: Hardens surface layer keeping core soft.

Q18: The main advantage of electroplating is:

a) Improves mechanical strength
b) Adds decorative and corrosion resistance layer
c) Changes metal structure
d) Removes surface cracks
Ans: b) Adds decorative and corrosion resistance layer
Explanation: Electroplating provides surface protection and aesthetics.

Q19: Which process uses chromium plating to improve hardness and corrosion
resistance?
a) Anodizing
b) Electroplating
c) Burnishing
d) Polishing
Ans: b) Electroplating
Explanation: Chromium plating is a common electroplating process.

Q20: Heat treatment performed after quenching to reduce brittleness is:

a) Tempering
b) Annealing
c) Normalizing
d) Hardening
Ans: a) Tempering
Explanation: Tempering balances hardness and toughness.

Q21: Which finishing process is eco-friendlier and does not involve heavy metals?
a) Electroplating
b) Anodizing
c) Galvanizing
d) Chromate conversion coating
Ans: b) Anodizing
Explanation: Anodizing uses aluminum oxide layers, less toxic than plating.

Q22: Hot-dip galvanizing involves:

a) Immersing steel in molten zinc
b) Electroplating zinc
c) Painting zinc coating
d) Chemical vapor deposition
Ans: a) Immersing steel in molten zinc
Explanation: Hot-dip galvanizing gives thick zinc coating.

Q23: Which heat treatment process refines microstructure for better machinability?
a) Annealing
b) Normalizing
c) Quenching
d) Tempering
Ans: b) Normalizing
Explanation: Normalizing produces uniform grain structure.

Q24: Passivation is a chemical process used to:

a) Harden steel surface
b) Form protective oxide film on stainless steel
c) Polish surface
d) Remove rust mechanically
Ans: b) Form protective oxide film on stainless steel
Explanation: Passivation prevents corrosion by oxide layer.

Q25: Which of the following is NOT a heat treatment?

a) Nitriding
b) Electroplating
c) Carburizing
d) Tempering
Ans: b) Electroplating
Explanation: Electroplating is surface coating, not heat treatment.