Engineering Materials and Processes Quiz

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Questions and Answers

What is a significant advantage of the ECM method in terms of the condition of the workpiece?

The workpiece is subjected to high cutting forces.

The workpiece remains in an undisturbed, stress-free state. (correct)

The workpiece is automatically shaped during the process.

The workpiece experiences high temperatures during machining.

Which of the following is NOT a limitation of the ECM process?

Complicated tool design methods.

Large power consumption issues.

Ability to achieve sharp internal corners.

Extra surface polishing required post-machining. (correct)

What must be maintained constant for the ECM method to be effective?

Tool speed.

Current density.

Voltage. (correct)

Temperature.

Which characteristic demonstrates the versatility of ECM compared to conventional methods?

Absence of tool wear. Signup and view all the answers

What happens to the metal removal rate at low current densities in ECM?

It decreases significantly. Signup and view all the answers

Which material is NOT commonly used to make saw blades?

Aluminum alloy Signup and view all the answers

What is the purpose of tooth set in a saw blade?

To make the kerf wider than the blade thickness Signup and view all the answers

Which tooth form is better suited for finer pitches?

Straight tooth form Signup and view all the answers

Which of the following is a characteristic of the wavy tooth set?

Every two consecutive teeth are offset in the same direction Signup and view all the answers

Tooth spacing or pitch influences which of the following aspects of a saw blade?

The suitable tooth set type Signup and view all the answers

What is the primary advantage of using a tooth form with more metal backing?

It provides better cutting durability Signup and view all the answers

Which characteristic is least affected by the size of the saw blade?

Thickness of the cutting edge Signup and view all the answers

Which material has the best wear ratio when used as an electrode in EDM?

Graphite Signup and view all the answers

What is the typical wear ratio for brass electrodes in EDM?

1:1 Signup and view all the answers

Which of the following factors does NOT significantly affect the choice of electrode material?

Aesthetic appeal Signup and view all the answers

How does the metal removal rate typically change with increasing current density in EDM?

It increases. Signup and view all the answers

What does the servo-mechanism control in the EDM process?

The gap between the tool and workpiece. Signup and view all the answers

What voltage condition prompts the servo control to adjust the movement of the electrode?

Voltage drop across the gap. Signup and view all the answers

What is the expected general tolerance achievable in EDM machining?

±0.05 to ±0.13 mm Signup and view all the answers

For optimal machining efficiency in EDM, what should be maintained despite tool wear?

Constant gap. Signup and view all the answers

What is the primary disadvantage of using normal metallic electrodes in EDM regarding wear?

They have a high wear ratio. Signup and view all the answers

What is commonly done to achieve a better surface finish in EDM processes?

Performing a roughing cut followed by a finishing cut. Signup and view all the answers

Which non-traditional machining method is specifically suitable for micro-machining and drilling?

LBM Signup and view all the answers

What is the gap measurement in mm for EDM according to the given parameters?

0.20 Signup and view all the answers

Which medium is used in Abrasive Jet Machining (AJM)?

Air Signup and view all the answers

In terms of power output, which of the following non-traditional machining methods has the highest power rating?

ECM Signup and view all the answers

Which non-traditional machining method is primarily used for cavity sinking and standard hole drilling?

EDM Signup and view all the answers

What electrical potential range is used in Electrical Discharge Machining (EDM)?

100 - 300 V Signup and view all the answers

Which method is known for its capability in fine hole drilling and contour machining?

ECM Signup and view all the answers

Which physical parameter for Unconventional Machining Methods represents the current used in Electron Beam Machining (EBM)?

500 A Signup and view all the answers

What is a defining characteristic of Plasma Arc Machining (PAM)?

Suitable for clean, rapid cuts and profiles Signup and view all the answers

What is the primary purpose of the dielectric fluid in the wheel face grinding process?

To flush away metal chips from the cutting area Signup and view all the answers

What is the typical range for the spark gap in the grinding process?

0.013 to 0.076 mm Signup and view all the answers

Which of the following operations is NOT suited for Electro-Dynamic Grinding (EDG)?

High-speed continuous machining Signup and view all the answers

What mechanism is used to control the spark gap in the grinding process?

Servomechanism Signup and view all the answers

At what speed is the graphite wheel typically rotated in the EDG process?

0.5 to 3 m/s Signup and view all the answers

Which characteristic of Electro-Dynamic Grinding allows it to avoid wheel loading?

Combination of grinding carbide and steel Signup and view all the answers

What principle does Electro-Chemical Machining (ECM) utilize?

Electrolysis Signup and view all the answers

For which of the following situations is the EDG method particularly effective?

Grinding through complex forms Signup and view all the answers

Which of these is one of the main applications of EDG?

Grinding circular forms Signup and view all the answers

What is a key advantage of using EDG over traditional abrasive wheel methods?

Reduced likelihood of fracturing delicate components Signup and view all the answers

What is the main function of a vertical broaching machine's slide?

To guide the broaching tool accurately Signup and view all the answers

In vertical pull down broaching, where is the broach positioned when it starts the machining process?

In the base of the machine Signup and view all the answers

What adjustment feature is present in a vertical broaching machine to accommodate different broaching operations?

Speed control of the slide Signup and view all the answers

What is the purpose of the worktable in a vertical broaching machine?

To facilitate loading and unloading of the workpiece Signup and view all the answers

In the context of broaching, what defines external surface broaches?

They are classified based on the surface they machine into. Signup and view all the answers

What mechanism does the vertical pull-up broaching machine utilize to begin the machining process?

Pulling the broach upward after workpiece clamping Signup and view all the answers

Which feature distinguishes a vertical broaching machine from traditional cutting methods?

It primarily relies on hydraulic drive systems Signup and view all the answers

Which advantage of the non-traditional machining method significantly enhances the production of complicated die shapes?

Elimination of mold division lines Signup and view all the answers

What characteristic of the Electric Discharge Grinding (EDG) process distinguishes it from traditional grinding methods?

Involvement of high frequency electrical discharges Signup and view all the answers

How does the implementation of a single machine for die manufacturing affect the overall cycle time?

It allows for concurrent processing reducing total cycle time Signup and view all the answers

Which factor contributes to avoiding rejections in the machining process?

Initial planning and program checks Signup and view all the answers

What advantage does the high surface finish achieved in this machining method confer?

Reduced manual finishing operation time Signup and view all the answers

How does the design technique improvement affect layout in compound dies?

It enables easier and more efficient layout Signup and view all the answers

What is the range of time required for production in this non-traditional machining process?

1 hour to 20 hours Signup and view all the answers

Which feature of the machining process contributes to high repeatability in production?

Single piece construction of dies Signup and view all the answers

What is the primary benefit of being able to run the WCEDM process continuously?

Maximized uptime and productivity Signup and view all the answers

Which material category is particularly effective when machined using the method described?

Electrically conductive materials Signup and view all the answers

What is the primary distinction between chemical blanking and contour machining in chemical milling?

Chemical blanking etches entirely through the workpiece, while contour machining selectively removes material. Signup and view all the answers

What is the approximate tolerance achievable in chemical milling based on the depth of etch?

±0.05 mm per 2.54 mm of depth. Signup and view all the answers

Which of the following is a limitation of the chemical milling process?

The metal removal rate is comparatively slow. Signup and view all the answers

In chemical milling, what effect do surface imperfections have on the etching process?

They can cause faster etching rates in the affected areas. Signup and view all the answers

What is the typical range of surface finish values achievable in chemical milling?

0.25 to 6.25 μmRa values. Signup and view all the answers

What is a key operational feature of the vertical double slide surface broaching machine?

One slide works while the other returns to its starting position. Signup and view all the answers

In the context of continuous surface broaching machines, what role do the fixtures play?

They hold and locate workpieces at set intervals on the chain. Signup and view all the answers

What is a distinctive characteristic of the cutting speed in a horizontal surface broaching machine?

It varies between 3 to 12 meters per minute. Signup and view all the answers

What is a major advantage of using hydraulic drives in broaching machines?

They are less expensive and produce smoother actions. Signup and view all the answers

How does a continuous surface broaching machine enhance productivity?

Through automatic loading and unloading of workpieces. Signup and view all the answers

Which statement accurately describes the operational mechanism for broaching tools?

They are reciprocated using hydraulic or electro-mechanical drives. Signup and view all the answers

What is the purpose of the rigid guiding member in a continuous surface broaching machine?

To stabilize the movement of the chain and ensure uniform stock removal. Signup and view all the answers

In a horizontal surface broaching machine, which factor most influences the operational efficiency?

The speed range of the broaching tool. Signup and view all the answers

In the context of electro-mechanical drives for broaching, what issue might arise with using longer strokes?

They can lead to increased mechanical wear. Signup and view all the answers

What is the cutting speed for mild steel when using tungsten H.S.S. blades?

0.75 m/s Signup and view all the answers

Which type of sawing machine operates solely on the forward stroke?

Power Hacksaw Signup and view all the answers

What determines the size of a power hacksaw?

The largest diameter or square that can be cut Signup and view all the answers

What is typically required in the operation of a power hacksaw for materials except cast iron?

Flooding with cutting fluid Signup and view all the answers

For circular saws over 250 mm in diameter, what is a common construction type used?

Segmental or inserted-blade construction Signup and view all the answers

Which of the following materials has the highest cutting speed when using tungsten H.S.S. blades?

Brass and Aluminium Signup and view all the answers

What is the thickness range of circular cold saws?

1/32 to 1/12 inch Signup and view all the answers

What is the typical role of the saw frame in a power hacksaw?

To hold the blade during operation Signup and view all the answers

What operational feature may automatically stop a power hacksaw after completing a cut?

An automatic switch Signup and view all the answers

In milling operations using circular saws, what type of slit do they create?

Narrow slits Signup and view all the answers

Study Notes

Broaching Machines

Broaches are tools used for machining internal or external shapes in a single stroke.
Types include horizontal and vertical machines, pull and push.
Tooth elements include front rake angle (hook angle), back-off angle (relief angle).
Materials commonly used are high-speed steel (HSS), brazed carbides, or disposable inserts; carbide tools can be used for machining cast iron with close tolerances.
Broaching machines feature a work-holding fixture, broaching tool, drive mechanism, and a frame.
Construction may be either solid, assembled, or built from replaceable sections or teeth for easy repair.

Types of Broaching Machines

A horizontal machine's slide travels horizontally; the work area is accessible from the floor, allowing greater slide support for straightness.
A vertical machine's slide travels vertically; this design often utilizes a pit or elevated platform to keep workers at the work station.
There are both pull and push broaching machines. Pull machines place tension on the broach; push machines use compressive forces.

Internal Broaching

Pull broaching machines apply force to the shank, putting the broach in tension. This pulls the broach through the workpiece.
Push broaches apply force in compression to the end of the broach. The broach is shorter than a pull broach, usually not exceeding 15 diameters.

Surface Broaching Machines

Classified by the surface they work on: flat (slab), peripheral, and contour broaches.

Broaching Drives

Hydraulic drives are smoother and are more commonly used.
Electro-mechanical drives are preferred for longer strokes or high-speed applications.

Broach Size

Machine size is represented by two numbers: "a x b".
'a': Force the machine can apply in tonnes
'b': Stroke of the slide in millimeters

Broaching Advantages

Fast operation, removing all machining allowance in a single stroke
High production capacity
High surface quality
Internal and external machining capability
Allows for repair through replaceable sections.

Broaching Limitations

High tool cost
Requires a unique broach for each shape/size
Workpiece needs to be rigidly held and the broach firmly guided.
Not suitable for large metal removal amounts

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Description

Test your knowledge on the Electrochemical Machining (ECM) process and saw blade characteristics. This quiz covers key advantages, limitations, and related machining concepts. Boost your understanding of these engineering processes by answering the questions accurately.