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in

R2017
ME8073 - UNCONVENTIONAL MACHINING PROCESSES
Multi Choice Questions (MCQ)
UNIT II - THERMAL AND ELECTRICAL ENERGY BASED PROCESSES
[Syllabus]

[Electric Discharge Machining (EDM) – Wire cut EDM – Working Principle-equipments-

Process Parameters-Surface Finish and MRR- electrode / Tool – Power and control Circuits-
Tool Wear – Dielectric – Flushing –– Applications. Laser Beam machining and drilling,
(LBM), plasma, Arc machining (PAM) and Electron Beam Machining (EBM). Principles –
Equipment –Types - Beam control techniques – Applications]

Electric Discharge Machining (EDM) – Introduction

1. In advanced machining processes, what is the full form of EDM?
a) Electro discharge Machining
b) Electro discharge Manufacturing
c) Electrical dimensioning Machining
d) Electrode dimensions Manufacturing

Answer: a
Explanation: Full form of EDM in advanced machining processes is, Electrodischarge
machining.

2. The evolution of wire EDM took place in which part of history?

a) 1940s
b) 1950s
c) 1960s
d) 1970s

Answer: d
Explanation: Evolution of wire EDM in 1970s was due to powerful generators, new wire
electrodes, improved machining intelligence and better flushing.

3. Machining speeds have gone up to how many times after the invention of EDM?
a) Ten
b) Twenty
c) Thirty
d) Fifty

Answer: b
Explanation: Machining speeds have gone up to 20 times after the invention of EDM.

4. By using EDM, how much percentage of machining costs can be reduced?

a) 10 %
b) 20 %
c) 30 %
d) 50 %

Answer: c
Explanation: EDM decreased the machined cost at least by 30 %.

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5. After invention of EDM, surface finish have improved by how much factor?
a) 10
b) 15
c) 20
d) 25

Answer: b
Explanation: Surface finish have been improved by a factor of 15 after the invention of EDM.

6. Cavities with, which of the following factors can be produced using Electro discharge
machining?
a) Thin walls
b) Fine features
c) Thin walls & Fine features
d) None of the mentioned

Answer: c
Explanation: Cavities with thin walls and fine features can be machined using EDM.

7. Which of the following geometries can be machined using EDM?

a) Simple
b) Complex
c) Difficult to cut
d) All of the mentioned

Answer: d
Explanation: Electrodischarge machining can be used for simple as well as complex
geometries.

8. State whether the following statement is true or false regarding EDM.

“In EDM, process is affected by hardness of material.”
a) True
b) False

Answer: b
Explanation: EDM process is not affected by the hardness of material.

9. How much amount of burr is produced in this process?

a) 10 %
b) 40 %
c) 70 %
d) No burr

Answer: d
Explanation: Electro discharge machining is a burr free process.

10. Which of the following mechanisms is used for material removal?

a) Electro discharge erosion
b) Magnetic abrasion
c) Electro chemical dissolution
d) Mechanical erosion

Answer: a
Explanation: Material is removed by electro-discharge erosion (EDE) in EDM

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EDM-Mechanism of Material Removal

11. What is the value of order of frequency applied between the two electrodes in EDM?
a) 1 kHz
b) 3 kHz
c) 5 kHz
d) 7 kHz

Answer: c
Explanation: The magnitude of frequency applied between the electrodes in EDM is about 5
kHz.

12. What are the magnitude of voltages used in Electro discharge machining?
a) 1 to 20 V
b) 20 to 120 V
c) 120 to 220 V
d) 220 to 320 V

Answer: b
Explanation: In EDM, the magnitude of voltages range between 20 and 120 V.

13. What are the values of gaps between the electrodes in EDM?
a) 0.001 – 0.05 mm
b) 0.01 – 0.5 mm
c) 0.1 – 5 mm
d) 1 – 15 mm

Answer: b
Explanation: In EDM, very small gaps that range between 0.01 – 0.5 mm are maintained.

14. How is material removed in Electro discharge machining?

a) Melt and evaporate
b) Corrode and break
c) Mechanical erosion takes place
d) None of the mentioned

Answer: a
Explanation: In Electro discharge machining, material is melted and then evaporated.

15. What is the radius of channel, when electrical breakdown occur?

a) 4 µm
b) 6 µm
c) 8 µm
d) 10 µm

Answer: d
Explanation: In EDM, the electrical breakdown occurs in dielectric in a channel of radius
about 10 µm.

16. State whether the following statement is true or false regarding EDM.
“In EDM, negative ions (electrons) collide with positive ions to generate heat.”
a) True
b) False

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Answer: b
Explanation: In Electro discharge machining, electrons collide with neutral atoms producing
positive ions and further electrons.

17. What are the values of temperature that are obtained while machining using EDM?
a) 2000 to 3000ᵒC
b) 4000 to 6000ᵒC
c) 8000 to 12000ᵒC
d) 15000 to 20000ᵒC

Answer: c
Explanation: The temperatures obtained when the ions reach their respective electrodes,
range between 8000ᵒC and 12000ᵒC.

18. What range of heat fluxes are obtained while machining using EDM?
a) 1017 W/m2
b) 1019 W/m2
c) 1024 W/m2
d) 1027 W/m2

Answer: a
Explanation: Heat flux up to the value of 10 17 W/m2 are obtained in EDM.

19. What is the duration of sparks that are produced in Electro discharge machining?
a) 0.001 – 1 µs
b) 0.1 – 2000 µs
c) 0.2 – 100 ms
d) 100 – 2000 ms

Answer: b
Explanation: Duration of spark in Electro discharge machining is about 0.1 to 2000 µs.

20. State whether the following statement is true or false about material removal in EDM.
“In EDM, high pressures allow the metal to evaporate.”
a) True
b) False

Answer: b
Explanation: High pressures in EDM try to prevent the super-heated metal from evaporation.

21. What are the values of pressure of the plasma in EDM?

a) Up to 2 atm
b) Up to 20 atm
c) Up to 200 atm
d) Up to 2000 atm

Answer: c
Explanation: Pressure on the plasma channel rises to values as high as 200 atm when
dielectric evaporates.

22. At the end of pulse, super-heated metal evaporates _______________

a) Explosively
b) Normally
c) Periodically

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d) Occasionally

Answer: a
Explanation: At the end of pulse, pressure drops suddenly and super-heated metal
evaporates explosively.

23. After the explosion is over, how is the debris carried away?
a) Evaporation
b) Fresh dielectric
c) Old dielectric
d) All of the mentioned

Answer: b
Explanation: Debris is carried away by the fresh dielectric that rushes in.

24. The layer formed when un expelled molten metal solidifies is known as ___________
a) Reabsorbed layer
b) Recast layer
c) Un evaporated layer
d) Condensed layer

Answer: b
Explanation: Unexpelled molten metal solidifies to form a layer known as recast layer.

25. Amount of material removed from anode and cathode depend on which of the following?
a) Electrons
b) Positive ions
c) Electrons & Positive ions
d) None of the mentioned

Answer: c
Explanation: The amount of material removed from electrodes depend on the contribution of
the charged ions.

26. What happens when the electron current predominates in the discharge?
a) More anodic removal
b) More cathodic removal
c) Remains same
d) All of the mentioned

Answer: a
Explanation: When electron current predominates the electrical discharge, anodic material
removal is greater than cathodic material.

27. Between what values mentioned below, do the discharges and sparks usually vary?
a) 1 and 10,000
b) 500 and 500,000
c) 500,000 and 1,000,000
d) None of the mentioned

Answer: b
Explanation: Frequency of discharges or sparks generally vary between 500 and 500,000
sparks per second.

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28. What is the value of gap maintained between the electrodes when we use servo
mechanism?
a) 10 – 100 µm
b) 100 – 200 µm
c) 200 – 500 µm
d) 500 – 1000 µm

Answer: c
Explanation: In EDM, value of gap maintained between the electrodes range between 200
and 500 µm.

29. Based on the electrode gap, which of the following electric pulses are generated?
a) Open Circuit pulses
b) Sparks
c) Arcs
d) All of the mentioned

Answer: d
Explanation: Based on the electrode gap, electric pulses are distinguished which are – circuit
pulses, sparks, arcs and short circuits.

30. State whether the following statement is true or false regarding EDM.
“In Electro discharge machining, electric pulses generated affect the material removal.”
a) True
b) False

Answer: a
Explanation: In Electro discharge machining, electric pulses generated have an impact on
the material removal.

31. Open gap voltages contribute to how much amount of material removal?
a) 20 %
b) 50 %
c) 70 %
d) No contribution

Answer: d
Explanation: Open gap voltage that occur at too large distances do not contribute to any
material removal.

32. When the electrode gap is too small or electrodes are in contact, how much material is
removed?
a) 10%
b) 20%
c) 30%
d) No material removed

Answer: d
Explanation: When electrodes come in contact with one another, short circuits occur and
material removed is not possible.

33. Which components mentioned below are affected due to arcs?

a) Work piece
b) Tool
c) Work piece & Tool

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d) None of the mentioned

Answer: c
Explanation: Arcs are believed to occur at same spots on electrode surfaces which damage
both tool and work piece.

34. Which of the following pulses contribute to the desired material removal in EDM?
a) Open circuit pulses
b) Short circuits
c) Arcs
d) Sparks

Answer: d
Explanation: The sparks are the one which contributes to the desired material removal in
Electro discharge machining.

EDM-Machining System
35. Which of the following are main components of EDM?
a) Dielectric system
b) Servomechanism
c) Power supply
d) All of the mentioned

Answer: d
Explanation: Main components of machining system in EDM are – dielectric system, power
supply and servomechanism.

36. What is the function of feed-control system in Electro discharge machining?

a) Constant gap
b) Supply power
c) Dielectric fluid supply
d) Work piece holding

Answer: a
Explanation: Feed control system is used to maintain constant gap between electrodes.

37. What is the use of power supply system in Electro discharge machining?
a) Constant gap
b) Supply power
c) Dielectric fluid supply
d) Work piece holding

Answer: b
Explanation: Power supply system is used to supply pulses at certain voltages, current, on
time and off time.

38. What is the function of dielectric circulation unit in Electro discharge machining?
a) Constant gap
b) Supply power
c) Dielectric fluid supply
d) Work piece holding

Answer: c
Explanation: Dielectric circulation unit is used to supply dielectric fluid for flushing.

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39. Which of the following materials are used as electrodes in EDM?

a) Graphite
b) Copper
c) Brass
d) All of the mentioned

Answer: d
Explanation: All the materials mentioned above, can be used as electrodes in Electro
discharge machining.

40. Metals with _________ melting point and _________ electrical conductivity are chosen
as tools in EDM.
a) Low, good
b) Low, bad
c) High, good
d) High, bad

Answer: c
Explanation: In EDM, metals with high melting point and good electrical conductivity are
used as tools.

41. Copper has _________ Electro discharge machining wear and _________ conductivity.
a) Good, better
b) Good, worse
c) Bad, better
d) Bad, worse

Answer: a
Explanation: Cu is the metal which has better conductivity and good electro discharge
machining wear.

42. Which of the following tungsten carbides are used as electrodes in EDM?
a) Silver tungsten
b) Copper tungsten
c) All of the mentioned
d) None of the mentioned

Answer: c
Explanation: Both Silver tungsten and copper tungsten are the tungsten carbides used in
EDM.

43. State whether the following statement is true or false regarding materials used in Electro
discharge machining.
“In metals, copper graphite has less electrical conductivity than graphite.”
a) True
b) False

Answer: b
Explanation: Copper graphite has better electrical conductivity than graphite.

44. Brass metal ensures which type of sparking conditions in Electro discharge machining?
a) Stable
b) Unstable
c) Unsteady

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d) Insecure

Answer: a
Explanation: Brass is a type of metal which ensures stable sparking conditions in Electro
discharge machining.

45. In addition to the feed of tool, Electro discharge machining tool can have which type of
motion?
a) Oscillatory
b) Rotary
c) Vibrational
d) All of the mentioned

Answer: b
Explanation: In addition to feed, the tool electrode may have rotary or orbiting motion.

46. Which of the following parameters determines the size of cavities?

a) Size of electrode
b) Radius of orbit
c) All of the mentioned
d) None of the mentioned

Answer: c
Explanation: Size of electrode and radius of orbit determines the size of cavities in EDM.

47. Electrode orbiting ________ the flushing of dielectric fluid in Electro discharge
machining.
a) Improves
b) Decreases
c) Reduces
d) Degrades

Answer: a
Explanation: The additional orbiting motion of electrodes helps in improving the flushing by
creating a pumping effect of dielectric liquid.

48. Quality of hole produced by orbiting motion is _________ to that obtained by using
stationary electrode.
a) Inferior
b) Superior
c) Lower
d) All of the mentioned

Answer: b
Explanation: Quality of hole produced by orbiting motion is superior to that obtained by using
stationary electrode.

49. In EDM, electrode polarity depends up on which of the following components?

a) Work piece
b) Electrode material
c) All of the mentioned
d) None of the mentioned

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Answer: c
Explanation: In Electro discharge machining, electrode polarity depends on both work piece
and electrode material

50. Which one among the following, is the most important factor in determining the tool
wear?
a) Melting point
b) Boiling point
c) Power supplied
d) Feed rate

Answer: a
Explanation: In EDM, melting point is the most important factor in determining the tool wear.

51. Electrode wear ratios can be expressed as, which of the following wears?
a) End wear
b) Side wear
c) Corner wear
d) All of the mentioned

Answer: d
Explanation: Electrode wear ratios are expressed as end wear, corner wear, side wear and
volume wear.

52. The term no wear in EDM occurs when electro-to-work piece wear ratio is __________
a) <1%
b) <3%
c) <5%
d) <10%

Answer: a
Explanation: In Electro discharge machining, no wear is the term used when the electrode-
to-work piece ratio is less than 1%.

53. Which of the following are the other factors that influence the electrode wear?
a) Voltage
b) Current
c) Electrode material
d) All of the mentioned

Answer: d
Explanation: In EDM, electrode wear depends on the factors such as voltage, current,
electrode material and polarity.

54. State whether the following statement is true or false regarding wear in EDM.
“In EDM, electrode wear is less dominant when it comes to micromachining
applications.”
a) True
b) False

Answer: b
Explanation: Electrode wear is more when it comes to micromachining applications in EDM.
55. State whether the following statement is true or false regarding wear in EDM.
“In EDM, corner wear ratio does not depend on type of electrode material.”
a) True

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b) False

Answer: b
Explanation: In EDM, corner wear ratio depend on the material of electrode used.

56. In Electro discharge machining, highest wear ratio is associated with which type of
melting point?
a) Low
b) Medium
c) High
d) Very high

Answer: a
Explanation: In Electro discharge machining, lowering of the melting point of electrode
material results in high wear ratio.

57. Which of the following is not a function of dielectric in EDM?

a) Flush particles
b) Cool the section
c) Maintain voltage
d) Provide insulation

Answer: c
Explanation: Flushing particles, providing insulation and cooling the sections that are heated,
are the functions of dielectric.

58. Which of the following are the main requirements of dielectric fluids?
a) Viscosity
b) High flash point
c) Minimum odour
d) All of the mentioned

Answer: d
Explanation: Adequate viscosity, high flash point, oxidation stability, minimum odour, low
cost and good electrical discharge are the main requirements of dielectric fluids.

59. Which of the following can be used as dielectric fluids in EDM?

a) Kerosene
b) Silicon fluids
c) Distilled water
d) All of the mentioned

Answer: d
Explanation: The dielectric fluids used are kerosene, silicon fluid, ethylene glycol, water in
emulsions and distilled water.

60. In EDM, inadequate flushing will not result in which of the following consequences?
a) Arcing
b) Debris removal
c) Decrease electrode life
d) Increased production time

Answer: b
Explanation: Inadequate flushing in Electro discharge machining results in less removal or
no removal of debris.

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61. Which methods below, are used for introducing the dielectric in machining gap?
a) Normal flow
b) Reverse flow
c) Jet flushing
d) All of the mentioned

Answer: d
Explanation: Four methods namely normal flow, reverse flow, jet flushing and immersion
flushing are used for introducing dielectric.

62. Few large holes are _________ than many small flushing holes in Electro discharge
machining.
a) Worse
b) Better
c) Well
d) None of the mentioned

Answer: a
Explanation: Many small holes are better than a few large holes in machining thorough the
EDM process.

63. State whether the following statement is true or false regarding the dielectric in EDM.
“In EDM, flushing through the tool is more preferred than side flushing.”
a) True
b) False

Answer: a
Explanation: Flushing through the tool is preferred than side flushing for deep cuts.

64. In Electro discharge machining, which type of dielectric flow mentioned below is
desirable?
a) Unsteady flow
b) Steady flow
c) Unstable flow
d) None of the mentioned

Answer: b
Explanation: In EDM, steady dielectric flow on the entire electrode-work piece interfaces is
most desirable

EDM-Material Removal Rate

65. Metal is removed on which of the components in electro discharge machining?
a) Electrode tool
b) Work piece
c) Electrode tool & Work piece
d) None of the mentioned

Answer: c
Explanation: In Electro discharge machining, material is removed from both tool and work
piece.
66. On which of the following components, does the MRR depend?
a) Work piece
b) Electrode tool

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c) Electrode tool & Work piece

d) None of the mentioned

Answer: c
Explanation: Material removal rate not only depends on work piece material but also the tool
material.

67. Which of the following factors influence the material removal rate?
a) Pulse condition
b) Electrode polarity
c) Machining medium
d) All of the mentioned

Answer: d
Explanation: The factors such as pulse conditions, electrode polarity and machining medium
also affect the material removal rate.

68. In Electro discharge machining, materials with low melting point have which type of
material removal rate?
a) Very low
b) Low
c) Medium
d) High

Answer: d
Explanation: In Electro discharge machining, materials having low melting point have high
material removal rates and vice-versa.

69. In Electro discharge machining, materials with low melting point have which type of
surface roughness?
a) Rough
b) Smooth
c) Fine
d) All of the mentioned

Answer: a
Explanation: In Electro discharge machining, materials having low melting point have high
rougher surfaces and vice-versa.

70. What are the values of material removal rates in EDM?

a) 0.001 to 0.1 mm3/min
b) 0.1 to 400 mm3/min
c) 400 to 1000 mm3/min
d) 1000 to 5000 mm3/min

Answer: b
Explanation: In EDM, material removal rates range from 0.10 to 400 mm 3/min.

71. What happens to the material removal rate if the sparks are very less in EDM?
a) Decreases
b) Increases
c) Increase and then decrease
d) All of the mentioned

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Answer: a
Explanation: In EDM, if sparks generated are less then material removal rate decreases.

72. What is the relation between the melting point and the material removal rate?
a) Directly Proportional
b) Inversely proportional
c) Indirectly proportional
d) None of the mentioned

Answer: b
Explanation: In Electro discharge machining, material removal rate is inversely proportional
to the melting point.

73. What happens to the crater size if we increase the current keeping the pulse time
constant?
a) Increase
b) Decrease
c) Decrease and increase
d) None of the mentioned

Answer: a
Explanation: By keeping pulse time constant and increasing current, crater size also
increases.

74. What happens to the crater size if we decrease the pulse time keeping the current
constant?
a) Increase
b) Decrease
c) Increase and decrease
d) None of the mentioned

Answer: b
Explanation: By decreasing pulse time and keeping current constant, crater size also
decreases

EDM-Surface Integrity
75. On which of the following factors do the craters depend?
a) Physical properties
b) Mechanical properties
c) Composition of medium
d) All of the mentioned

Answer: d
Explanation: In EDM, craters depend on the physical and mechanical properties of material
and composition of medium.

76. The maximum depth of damaged layer is how many times that of average surface
roughness?
a) 1.5 time
b) 2 times
c) 2.5 times
d) 3 times

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Answer: c
Explanation: Depth of damaged layer is two and half times the average surface roughness
value.

77. What happens to the surface roughness values if the MRR increases in EDM?
a) Increases
b) Decreases
c) Decrease and increase
d) None of the mentioned

Answer: a
Explanation: In EDM, the surface roughness values increases linearly with increase in the
material removal rates.

78. State whether the following statement is true or false regarding the surface roughness in
EDM.
“In EDM, graphite electrodes produce smoother surfaces than metal ones.”
a) True
b) False

Answer: b
Explanation: In EDM, graphite electrodes produce rougher surfaces than that of the metal
ones.

79. In Electro discharge machining, what happens to the surface finish if the pulse energy is
decreased?
a) Reduces
b) Decreases
c) Improves
d) None of the mentioned

Answer: c
Explanation: In Electro discharge machining, the surface finish improves if the pulse energy
is decreased.

80. Using of a mate electrode in Electro discharge machining _____________ the surface
roughness of material.
a) Increases
b) Decreases
c) Enhances
d) None of the mentioned

Answer: b
Explanation: By using a mate electrode in Electro discharge machining, the surface
roughness values are decreased.

81. What happens to the surface roughness if oxygen gas is introduced in the gap?
a) Increases
b) Decreases
c) Decrease and then increase
d) All of the mentioned

Answer: b
Explanation: In EDM, surface roughness increases with the supply of oxygen gas in gaps.

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82. By how much percent surface roughness is reduced if we use proper dielectric flow?
a) 25%
b) 50%
c) 75%
d) 100%

Answer: b
Explanation: In Electro discharge machining, if we use a proper dielectric fluid flow, surface
roughness is decreased by 50 percent.

83. What are the tolerance values obtained by machining using EDM?
a) ± 10 mm
b) ± 15 mm
c) ± 25 mm
d) ± 40 mm

Answer: c
Explanation: The tolerance values of ± 25 mm are obtained when we machine components
using EDM.

84. How much extra tolerances are achieved when we choose proper variables?
a) ± 5 mm
b) ± 10 mm
c) ± 15 mm
d) ± 20 mm

Answer: a
Explanation: Extra tolerances of ± 5 mm are obtained with a proper choice of process
variables

EDM-Heat Affected Zone (HAZ)

85. What are the values of temperatures obtained in Electro discharge machining?
a) 1000 to 2000 oC
b) 2000 to 4000 oC
c) 4000 to 8000 oC
d) 8000 to 12000 oC

Answer: d
Explanation: The temperature attained while machining in Electro discharge machining are
from 8000 to 12000 oC.

86. What is the value of thickness of recast layer obtained when power of 5 µJ is given?
a) 1 µm
b) 3 µm
c) 5 µm
d) 7 µm

Answer: a
Explanation: When a power of 5 µJ is given, recast layer thickness of 1 µm is obtained.

87. What are the values of thickness of recast layers in Electro discharge machining?
a) 0.001 to 0.025 µm
b) 0.01 to 0.25 µm
c) 1 to 25 µm

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d) 10 to 250 µm

Answer: c
Explanation: In Electro discharge machining, the value of thickness of recast layers ranges
from 1 to 25 µm.

88. In Electro discharge machining, some annealing of the work piece can be expected
__________ the machined surface.
a) On
b) Just below
c) Above
d) At bottom

Answer: b
Explanation: Annealing of some part of the work piece in EDM can be expected just below
the machined surface.

89. The depth of the annealed surface is __________ to the amount of power used in
machining operation.
a) Directly proportional
b) Inversely proportional
c) Exponential
d) All of the mentioned

Answer: a
Explanation: The depth of annealed surface in EDM is proportional to the amount of power
used.

90. What are the values of thickness of annealed surface obtained while machining using
EDM?
a) 1 to 25 µm
b) 50 to 200 µm
c) 200 to 500 µm
d) 500 to 1000 µm

Answer: b
Explanation: Values of annealed surface thickness range from 50 µm to 200 µm.

91. In EDM, choosing electrodes that produce which type of machining reduces the
annealing effect?
a) Stable
b) Unstable
c) Uneven
d) All of the mentioned

Answer: a
Explanation: In Electro discharge machining, choosing the electrodes which produce more
stable machining reduces the annealing effect.

92. What happens to the fatigue strength of alloys if altered surfaces are produced in
Electro discharge machining?
a) Increases
b) Reduces
c) Enhances

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d) Improves

Answer: b
Explanation: The altered surface layers that are produced in Electro discharge machining,
significantly reduces the fatigue strength of alloys.

93. The altered layers formed during the process of EDM consists of which of the following?
a) Tempered layers
b) Heat affected zones
c) Intergranular precipitates
d) All of the mentioned

Answer: d
Explanation: Altered layers consists of recast layers, tempered layers, HAZs and
intergranular precipitates in EDM.

94. During roughing process through Electro discharge machining, what is the thickness of
layer formed?
a) <0.075 mm
b) <0.125 mm
c) <0.500 mm
d) <0.750 mm

Answer: b
Explanation: The thickness of layer obtained after machining is <0.127 mm in EDM.

95. During finishing process through Electro discharge machining, what is the value
thickness of layer formed?
a) <0.075 mm
b) <0.125 mm
c) <0.500 mm
d) <0.750 mm

Answer: a
Explanation: The thickness of layer obtained during EDM finishing is <0.075 mm.

96. Which of the following processes can be used for restoration of fatigue properties?
a) Low-stress grinding
b) Chemical machining
c) Reheat treatment
d) All of the mentioned

Answer: d
Explanation: For removal of altered layers processes such as low-stress grinding, chemical
machining, reheat treatment, metallurgical type coating and application of shot peening.

97. State whether the following statement is true or false regarding the HAZ in EDM.
“In EDM, post treatment to recover fatigue strength is not recommended.”
a) True
b) False

Answer: b
Explanation: After machining using EDM, post treatment to restore the fatigue strength is
recommended.

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EDM-Applications
98. Which of the following shapes can be produced using Electro discharge machining?
a) Complex shapes
b) Simple shapes
c) All of the mentioned
d) None of the mentioned

Answer: c
Explanation: Electro discharge machining is used to machine complex shapes to a high
degree of accuracy.

99. Which of the following materials can be machined using Electro discharge machining?
a) Heat resistant alloys
b) Super alloys
c) Carbides
d) All of the mentioned

Answer: d
Explanation: EDM is used to machine materials such as carbides, heat resistant and super
alloys which are difficult-to-machine materials.

100. Which of the following are the applications of Electro discharge machining?
a) Holes
b) Slots
c) Texturing
d) All of the mentioned

Answer: d
Explanation: Micromachining of holes, slots, dies, texturing, milling, surface modification and
mechanical pulsing are some typical applications of Electro discharge machining.

101. State whether the following statement is true or false regarding the applications of
EDM.
“In advanced machining processes, the incorporation of EDM with CIM increased the
length of time for unit operation.”
a) True
b) False

Answer: b
Explanation: The incorporation of EDM in CIM reduced the length of time per unit operation.

102. Which type of electrode is used for drilling in Electro discharge machining?
a) Flat electrode
b) Cuboidal electrode
c) Tubular electrode
d) Spherical electrode

Answer: c
Explanation: Tubular electrode is mostly preferred in Electro discharge machining, for drilling
purpose.
103. The dielectric fluid is flushed in thorough which part of the electrode in drilling in EDM?
a) Interior hole
b) Side gaps
c) All of the mentioned

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d) None of the mentioned

Answer: a
Explanation: EDM drilling uses a tubular electrode which flushes the dielectric thorough the
interior holes for removing debris.

104. Which type of holes can be produced through drilling using Electro discharge
machining?
a) Irregular
b) Curved
c) Tapered
d) All of the mentioned

Answer: d
Explanation: Drilling of work piece using EDM produced holes which can be irregular,
curved, tapered as well as inclined holes.

105. What are the values of general feed rates used for drilling in EDM?
a) 0.1 mm/min
b) 0.3 m/min
c) 0.5 mm/min
d) 0.7 mm/min

Answer: a
Explanation: Usually a feed rate of 0.10 mm/min is used for drilling the work piece using
Electro discharge machining.

106. What are range of diameter values obtained by drilling using EDM?
a) 0.01 to 0.05 mm
b) 0.1 to 0.5 mm
c) 1 to 5 mm
d) 10 to 15 mm

Answer: b
Explanation: Diameter values while drilled using Electro discharge machining, ranges from
0.10 to 0.50 mm.

107. What are the values of overcuts left behind after drilling of work piece?
a) 0.01 to 0.05 mm
b) 0.1 to 0.5 mm
c) 1 to 5 mm
d) 10 to 15 mm

Answer: a
Explanation: Overcut values from 0.01 to 0.05 mm are obtained after the drilling process in
EDM.

108. Electro discharge sawing is an application of EDM which employs __________ as tool
material.
a) Steel band
b) Disc
c) Steel band & Disc
d) None of the mentioned

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Answer: c
Explanation: Electro discharge sawing is an application of EDM which employs either steel
band or disc as tool.

109. When compared to the conventional abrasive sawing, how many times faster is the
MRR?
a) Twice
b) Thrice
c) Four
d) Five

Answer: a
Explanation: Electro discharge sawing cuts the work piece material at the rates which are
twice that of conventional abrasive sawing method.

110. How much amount of burr is produce while machined using Electro discharge
sawing?
a) 10%
b) 20%
c) 50%
d) No Burr

Answer: d
Explanation: The cuts produced in Electro discharge sawing have smaller kerf widths which
hav no burrs in it.

111. What are the values of finish obtained by machining work piece thorough Electro
discharge sawing?
a) 0.1 to 4 µm
b) 6.3 to 10 µm
c) 12.4 to 23 µm
d) 25.6 to 40 µm

Answer: b
Explanation: The finish obtained ranges from 6.3 to 10 µm when machined using Electro
discharge sawing.

112. What are the recast layer thickness values obtained in ED sawing?
a) 0.001 to 0.022 mm
b) 0.025 to 0.130 mm
c) 0.236 to 0.352 mm
d) 0.432 to 0.568 mm

Answer: b
Explanation: The recast layer thickness values obtained from ED sawing range from 0.025 to
0.13 mm

113. Which of the following electrodes are used for machining spherical surfaces in Electro
discharge machining?
a) Tubular electrodes
b) Flat electrodes
c) Cuboidal electrodes
d) All of the mentioned

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Answer: a
Explanation: Simple tubular electrodes are used to machine convex and concave spherical
surfaces.

114. What are the values of dimensional accuracy obtained while machining spherical
surfaces?
a) ± 1 µm
b) ± 3 µm
c) ± 5 µm
d) ± 7 µm

Answer: a
Explanation: Dimensional accuracy of ± 1 µm is obtained while machining spherical surfaces
using EDM.

115. What are the surface roughness values obtained while machining spherical surfaces
using Electro discharge machining?
a) <0.1 µm
b) <0.3 µm
c) <0.5 µm
d) <0.7 µm

Answer: a
Explanation: The surface roughness values obtained while machining of spherical surfaces
are <0.1 µm in Electro discharge machining.

116. Which motion of tool is used for machining spherical surfaces in Electro discharge
machining?
a) Oscillatory
b) Vibratory
c) Rotary
d) All of the mentioned

Answer: c
Explanation: The rotary motion tool is used for machining spherical surfaces of conducting
ceramic materials in EDM.

117. Which type of electrodes are used for milling application in Electro discharge
machining process?
a) Tubular type electrodes
b) Cylindrical type electrodes
c) Flat type electrodes
d) Spherical type electrodes

Answer: b
Explanation: Standard cylindrical electrodes are used for milling application in EDM process.

118. Which type of cavities can be machined using milling process by Electro discharge
machining?
a) Complex cavities
b) Simple cavities
c) Simple & Complex cavities
d) None of the mentioned

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Answer: c
Explanation: Simple cavities and complex cavities are machined by successive NC sweeps
of electrode over the desired path.

119. The simple electrodes are rotated at which speed for milling of work pieces in Electro
discharge machining?
a) Very low
b) Low
c) Medium
d) High

Answer: d
Explanation: Simple electrodes are rotated at high speeds for milling in Electro discharge
machining same as that of conventional milling.

120. What happens to the dielectric flushing while milling tool is rotated at a high speed in
EDM?
a) Improved
b) Worsen
c) Reduced
d) All of the mentioned

Answer: a
Explanation: Milling by electro discharge machining enhances the dielectric flushing due to
high speed rotation of tool.

121. State whether the following statement is true or false regarding the applications of
EDM.
“In EDM, milling process can machine complex shapes with sharp corners.”
a) True
b) False

Answer: b
Explanation: EDM milling has a main limitation i.e.., it cannot machine complex shapes with
sharp tools because of rotating tool.

122. Which of the following are the steps included in the die sinking process of EDM?
a) CAD of electrode
b) Electrode manufacturing
c) Programming for die sinking
d) All of the mentioned

Answer: d
Explanation: Designing of electrode, then manufacturing, and programming of die sinking
are the steps to be followed for die sinking process in EDM.

123. Wire EDM is a special form of Electro discharge machining which contains
__________ electrode.
a) Continuously moving
b) Periodically moving
c) Discontinuously moving
d) All of the mentioned

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Answer: a
Explanation: Wire EDM is a special type of EDM which uses a continuously moving
electrode for removal of material.

124. Which path of the components in wire EDM determines the path to be machined?
a) Horizontal worktable movement
b) Vertical worktable movement
c) Horizontal & Vertical worktable movement
d) None of the mentioned

Answer: a
Explanation: Horizontal movement of the work table determines the path to be machined in
Wire Electro discharge machining.

125. Which of the following materials are machined using Wire Electro discharge
machining?
a) Polycrystalline diamond
b) Cubic Boronitride
c) Matrix composites
d) All of the mentioned

Answer: d
Explanation: Polycrystalline diamond (PCD), cubic boron nitride (CBN) and other matrix
composites are the material than can be machined using wire EDM.

126. How much amount of burr is produce when we use Wire Electro discharge machining
for machining of work pieces?
a) 10%
b) 20%
c) No burr
d) Small amount

Answer: c
Explanation: In Wire Electro discharge machining no burr is produced without any distortion
while machining work pieces.

127. Which of the following industries use wire EDM for different applications?
a) Chemical industry
b) Aerospace industry
c) Automobile industry
d) All of the mentioned

Answer: d
Explanation: Industries such as chemical, aerospace, automobile, nuclear etc.., use wire
EDM for a wide variety of applications in their industries

128. While machining insulating ceramic materials using EDM, where is the sheet metal
placed?
a) Over material
b) Below material
c) Under material
d) None of the mentioned

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Answer: a
Explanation: Sheet metal is placed over the material in machining of insulating materials
using EDM.

129. Sparks occur between which of the following components?

a) Work piece and sheet metal
b) Tool electrode and sheet metal
c) Work piece and electrode
d) None of the mentioned

Answer: b
Explanation: Sparks occur between sheet metal and tool electrode for macining insulating
ceramics.

130. Texturing is applied to the steel sheets at which stages of cold rolling?
a) Initial stages
b) Middle stages
c) Final stages
d) All of the mentioned

Answer: a
Explanation: At the final stages of cold rolling, texturing is applied to the steel sheets.

131. What is the full form of EDT in EDM processes?

a) Electro discharge Tinplating
b) Electro discharge Texturing
c) Electro discharge Tapping
d) Electro discharge Turing

Answer: b
Explanation: Electro Discharge Texturing is a variant of EDM which is the full form of EDT.

132. Which of the following are the process variables for texturing process in EDM?
a) Pulse current
b) Electrode polarity
c) Dielectric type
d) All of the mentioned

Answer: d
Explanation: Pulse current, polarity, dielectric, electrode material and roll rotation speed are
some process variables of texturing.

133. What are the values of current amplitudes used in EDT?

a) 0.2 to 1 A
b) 2 to 10 A
c) 20 to 100 A
d) 40 to 200 A

Answer: b
Explanation: The values of current amplitudes in EDT range from 2 to 10 A.

134. What are duration values of current amplitude in EDT?

a) 0.1 to 1 µs
b) 1 to 10 µs
c) 10 to 100 µs

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d) 100 to 1000 µs

Answer: c
Explanation: Duration of current amplitudes used for EDT range from 10 to 100 µs.

135. What are the spindle rotation speeds used in EDT?

a) 1 to 4 rpm
b) 10 to 40 rpm
c) 20 to 60 rpm
d) 30 to 90 rpm

Answer: b
Explanation: Spindle rotation speeds for EDT process range from 10 to 40 rpm.

136. What are the values of diameter which are machined using Micro-EDM?
a) 0.001 to 0.01 mm
b) 0.01 to 0.1 mm
c) 0.1 to 1 mm
d) 1 to 10 mm

Answer: c
Explanation: Values of diameter in Micro-EDM range from 0.10 to 1.0 mm.

137. What happens to the machine capital cost in EDT when there is an increase in tool
quantity?
a) Decreases
b) Increases
c) Remains same
d) None of the mentioned

Answer: b
Explanation: With increase in tools quantity machine cost increases but texturing cost
reduces.

138. What is the value of depth to diameter ratio in Micro-Electro discharge machining
process?
a) 10:1
b) 5:2
c) 4:3
d) 2:1

Answer: a
Explanation: Value of the depth to diameter ratio in Micro-Electro discharge machining is
about 10:1.

139. What are the values of depths that can be machined using Micro-EDM?
a) 1 mm
b) 10 mm
c) 100 mm
d) 1000 mm

Answer: c
Explanation: Micro-Electro discharge machining can machine up to a depth of 100 mm in the
work piece material.

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140. What are the machining rates used in Micro-EDM process?

a) 0.1 to 2 mm/min
b) 1 to 20 mm/min
c) 10 to 200 mm/min
d) 100 to 500 mm/min

Answer: b
Explanation: Machining rates used in Micro-EDM process range from 1 to 20 mm/min.

141. What are the values of hole diameters obtained using Wire electro discharge grinding?
a) 1 µm
b) 3 µm
c) 5 µm
d) 7 µm

Answer: c
Explanation: Values of hole diameters up to 5 µm can be obtained using Wire electro
discharge grinding process.

142. What are the feed rates used in WEDG process?

a) 1 to 5 mm/min
b) 5 to 10 mm/min
c) 10 to 15 mm/min
d) 15 to 20 mm/min

Answer: b
Explanation: Feed rate values in WEDG process range from 5 to 10 mm/min

EDM-Process Control, Automation, Environmental Impact

143. Which of the following is a major difficulty in the Electro discharge machining process?
a) Proper sparks
b) Abnormal discharges
c) Optimum feed rates
d) No burr

Answer: b
Explanation: Avoidance of abnormal discharges has become a major difficulty in Electro
discharge machining process.

144. What has been done to the off time when there is a no-load voltage of electric
discharge?
a) Increased
b) Decreased
c) Reduced
d) Remains same

Answer: a
Explanation: The off time of pulse is increased in order to avoid the abnormal electric
discharges.

145. In a simple application which of the following parameters are inputs?

a) Pulse duration and current
b) Normal and abnormal pulses
c) All of the mentioned

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d) None of the mentioned

Answer: a
Explanation: Inputs used are pulse duration and current in a simple application.

146. In a simple application which of the following parameters are outputs?

a) Pulse duration and current
b) Normal and abnormal pulses
c) All of the mentioned
d) None of the mentioned

Answer: a
Explanation: Outputs used are normal and abnormal pulses in a simple application.

147. Which of the following are correlated with the machining conditions at output stage?
a) Machining depth
b) Surface roughness
c) Accuracy
d) All of the mentioned

Answer: d
Explanation: Machining depth, surface roughness, accuracy are correlated with the
machining conditions at the output stage.

148. How are EDM’s levels of integration when compared to conventional machining?
a) Slower rate
b) Faster rate
c) Same rate
d) None of the mentioned

Answer: a
Explanation: EDM’s levels of computer integration is at a slower rate when compared to
conventional machining processes.

149. Manufacturing of tool electrode undergoes which of the following processes?

a) Milling
b) Turning
c) Finishing
d) All of the mentioned

Answer: d
Explanation: The tool electrode manufacturing used in EDM has to undergo the basic
production processes such as milling, turning and finishing.

150. High temperatures produced in the working gap results in which of the following
potentials?
a) Hazardous smoke
b) Toxic vapours
c) Aerosols
d) All of the mentioned

Answer: d
Explanation: The temperatures in the working gap increases leading to hazardous smoke,
vapours and aerosols.

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151. Hydro carbons present in the dielectric fluid have impact on which of the body parts?
a) Eyes
b) Teeth
c) Skin
d) Nails

Answer: c
Explanation: Hydrocarbons present in dielectric fluids of EDM will have a negative impact on
the skin in our body.

152. What happens to the Electro discharge machining process under unfavourable
working conditions?
a) Will remain stable
b) Explosion may occur
c) Machining rate increases
d) Nothing happens

Answer: b
Explanation: Explosion occurs if Electro discharge machining is done under unfavourable
process variables and conditions.

153. Reduction in the electrical energy consumption will have impact on which aspects
mentioned below?
a) Environmental
b) Economic
c) Environmental & Economic
d) None of the mentioned

Answer: c
Explanation: The reduction of electric energy consumption has economic as well as
environmental benefits

Wire-cut EDM
Wire-cut EDM
154. A thin metallic wire used in wire-cut EDM is kept submerged in a tank of _____
a) dielectric fluid
b) pure water
c) molten metal
d) kerosene

Answer: a
Explanation: The Wire Electric Discharge Machining (WEDM) is a variation of EDM and is
commonly known as wire-cut EDM or wire cutting. In this process, a thin metallic wire is fed
onto the workpiece, which is submerged in a tank of dielectric fluid such as deionized water.

155. Wire-cut EDM can cut plates of thickness upto _____

a) 50mm
b) 100mm
c) 300mm
d) 500mm

Answer: c
Explanation: Wire-cut EDM process can cut plates as thick as 300mm and is used for

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making punches, tools and dies from hard metals that are difficult to machine with other
methods.

156. In WEDM, the wire is held tight between_____

a) upper and lower nozzles
b) upper and lower diamond guides
c) upper and lower groves in the handle
d) upper and lower pulleys

Answer: b
Explanation: In wire-cut EDM (WEDM), the wire which is constantly fed from a spool, is held
between upper and lower diamond guides. The guides are usually CNC-controlled and move
in the x–y plane.

157. The upper guide can move independently about_____

a) x-axis
b) y-axis
c) x-y-w axes
d) z-u-v axes

Answer: d
Explanation: On most machines, the upper guide can move independently about the z–u–v
axes, giving it the flexibility to cut tapered and transitioning shapes (example: square at the
bottom and circle on the top).

158. In the wire-cut EDM process, de-ionizing units are used for controlling the _____
a) feed rate
b) resistivity
c) burr formation
d) temperature of the wire

Answer: b
Explanation: In the wire-cut EDM process, water is commonly used as the dielectric fluid.
Filters and de-ionizing units are used for controlling the resistivity and other electrical
properties.

159. In the wire-cut EDM process, water is also used for _____
a) cooling
b) increasing the feed rate
c) flushing away the burr
d) controlling the cutting speed

Answer: c
Explanation: Apart from being used as a dielectric fluid, the water also helps in flushing away
the debris from the cutting zone. The flushing also helps to determine the feed rates to be
given for different thickness of the materials.

160. The WEDM process requires _____

a) lower initial investment
b) lesser cutting forces
c) a skilled operator
d) a coolant pump

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Answer: b
Explanation: The wire-cut EDM process requires lesser cutting forces in material removal;
hence it is generally used when lower residual stresses in the workpiece are desired.

161. The materials which are not stress-relieved before machining by WEDM process can
get distorted during machining.
a) True
b) False

Answer: a
Explanation: If the energy/power pulse is relatively low (as in finishing operations), little
changes in the mechanical properties of the material are expected due to residual stresses.
The components which are not stress-relieved earlier can get distorted in the machining
process.

162. During the WEDM process, workpiece undergoes a number of thermal cycles.
a) True
b) False

Answer: a
Explanation: In WEDM process, the selection of process parameters is very crucial, as in
some cases the workpiece undergoes significant thermal cycles the can be very severe.
These thermal cycles can form recast layers and induce residual tensile stresses on the
workpiece.

163. Electrically conductive materials are cut by WEDM process by _____ mechanism.
a) thermal
b) electro-thermal
c) electro-dynamic
d) fused metal

Answer: b
Explanation: Electrically conductive materials are cut by WEDM process by an electro-
thermal mechanism. In the WEDM process, the motion of the wire is slow. It is fed in the
programmed path and material is removed from the workpiece accordingly

164. In wire-cut EDM process, material removal takes place by a series of discrete
discharges between _____
a) di-electric fluid and the wire electrode
b) the wire-electrode and the workpiece
c) the workpiece and the CNC-table
d) wire electrodes

Answer: b
Explanation: In wire-cut EDM process, material removal takes place by a series of discrete
discharges between the wire and the workpiece in the presence of a di-electric fluid. Water is
commonly used as the di-electric fluid.

165. The di-electric fluid gets ionizes in between _____ gap.

a) tool-electrode
b) cathode-anode
c) workpiece-electrode
d) tool-workpiece

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Answer: a
Explanation: The di-electric fluid gets ionized in between the tool-electrode gap and hence,
helps in creating a path for each discharge. Because of these discharges, material is
removed from the workpiece.

166. The burr or cut particles are flushed away by the______

a) electrode
b) motion of the workpiece
c) di-electric fluid
d) coolant

Answer: c
Explanation: The area wherein discharge takes place gets heated to very high temperatures
such that the surface gets melted and removed. The cut particles (debris) get flushed away
by the continuously flowing dielectric fluid.

167. Wire-cut EDM (WEDM) process is widely used for _____

a) alloy steels
b) tool steels
c) stainless steels
d) carbon steels

Answer: b
Explanation: WEDM is a non-conventional process and is very widely used in tool steels for
a pattern and die making industries. The process is also used for cutting intricate shapes in
components used for the electric and aerospace industries.

168. For which of the following materials wire-cut EDM is not used?
a) Aluminium
b) Zirconium
c) Steels
d) Titanium

Answer: b
Explanation: Wire-cut EDM is used for cutting:
• Aluminium
• Brass
• Copper
• Graphite
• Steels
• Titanium.

169. WEDM process can be used for cutting hard extrusion dies.
a) True
b) False

Answer: a
Explanation: This process is used in the following areas:
• Aerospace, Medical, Electronics and Semiconductor applications
• Tool & Die making industries.
• For cutting the hard Extrusion Dies
• In making Fixtures, Gauges & Cams.

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170. WEDM process can be used for manufacturing of micro-tools.

a) True
b) False

Answer: a
Explanation: Following are the few areas where WEDM process is used:
• Cutting of Gears, Strippers, Punches and Dies
• Manufacturing hard Electrodes
• Manufacturing micro-tooling for Micro-EDM, Micro-USM and such other micromachining
applications.

171. How many subsystems are there in wire-cut EDM process?

a) 2
b) 3
c) 4
d) 5

Answer: c
Explanation: The subsystems of Wire-EDM process are:
• Power supply
• Di-electric system
• Wire feeding system
• Positioning system.

172. Di-electric system used in WEDM process is similar to that of the _____ process.
a) conventional drilling
b) conventional milling
c) conventional EDM
d) broaching

Answer: c
Explanation: The power supply and the di-electric system used in WEDM is very similar to
that of the conventional EDM. The main difference lies only in the type of di-electric used.

173. In wire-cut EDM, a moving wire is used to _____

a) remove the burr
b) cut complex outlines
c) melt the material
d) make the way for the di-electric fluid

Answer: b
Explanation: In wire-cut EDM, a moving wire is used to cut complex outlines and fine details
in the required workpiece. The wire is wound on a spool and is kept in constant tension

174. Wire electric discharge (ED) machining is based on the same principle as that of
_____
a) hydro-dynamic EDM
b) die-sink EDM
c) polar EDM
d) non-conventional EDM

Answer: b
Explanation: Wire electric discharge (ED) machining is based on the same principle as die-

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sink ED machining. The basic elements in all EDM methods are dielectric fluid, a workpiece
and an electrode.

175. The only difference between die-sink EDM and wire cut EDM is the _____
a) way of material removal
b) electrode used for the machining
c) type of materials machined
d) processing time

Answer: b
Explanation: In the die-sink EDM method the electrode has the same shapes as the wished
machining results. In the wire cut EDM method the electrode is a moving wire made from
some electrically conducting material. The workpiece is cut with the electrode wire.

176. During wire cut EDM, the size of the cavity produced by the wire while machining
depends upon _____
a) material of the workpiece
b) di-electric fluid used
c) wire material
d) electric current

Answer: d
Explanation: While machining a high electric current passes through the dielectric fluid and
heats the workpiece surface from a very small area. The corresponding workpiece area
melts and what is left, is a small round cavity. The cavity size depends on the electric current
and potential.

177. Sparking gap is the distance between _____

a) the workpiece and the CNC table
b) the workpiece and the electrode wire
c) the electrode wire and the di-electric fluid
d) the workpiece and the spark plug

Answer: b
Explanation: The distance between the electrode wire and the workpiece is called a sparking
gap. The electrode produces shapes that are a sparking gap dimension larger than the
programmed shape through which the electrode wire passes.

178. The absolute minimum inner corner radius is _____

a) the wire radius minus the sparking gap width
b) the sparking gap width minus the wire radius
c) the wire radius plus the sparking gap width
d) double of the wire radius

Answer: c
Explanation: The absolute minimum inner corner radius is the wire radius added with the
sparking gap width. Therefore during machining, the shapes produced have larger
dimensions as compared to the shapes mentioned in the program.

179. The wire ED machines have _____ programmable axes.

a) 2
b) 2-5
c) 6
d) 3-9

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Answer: b
Explanation: The wire cut EDM machines have 2 – 5 programmable axes. The machines
that are used in mould making applications typically have 5 programmable axes. These axes
are Wire guide, wire tilting in x and y –directions and workpiece or wire system movements
in x and y –directions.

180. Which of the following component of the wire cut EDM machine does not get heated?
a) Workpiece
b) Electrode wire
c) Di-electric fluid
d) Coils

Answer: b
Explanation: The electrode wire moves between two coils with a moderate speed. The part
of the wire that actually machines the workpiece is constantly changing. There is no time for
the wire to heat up.

181. Which of the following material properties sets restrictions to use wire cut EDM?
a) Material type
b) Melting point
c) Material hardness
d) Electrical conductivity

Answer: d
Explanation: As the electrode wire does not get heated during machining, the problems with
electrode wear are not an issue like in the case of die-sink ED machining and it is possible to
use wire cut EDM also for materials with high melting ranges. The material hardness sets no
restrictions. The only restriction is that the material needs to be electrically conductive.

182. Wires used in wire cut EDM are usually disposed after one usage.
a) True
b) False

Answer: a
Explanation: Despite the minimum wear, wires are usually disposed after one usage.
Sparking and high temperature during the machining reduces the wire tensile strength and
the wire could easily break if re-used.

183. The electrode wires are usually made form _____

a) graphite
b) iron
c) nickel
d) brass

Answer: d
Explanation: Wire used in wire cut EDM are usually made of brass – either zinc-coated or
uncoated. Brass wire can be purchased in different hardnesses and different diameters. Zinc
coated wire is used in machining high melting point workpiece materials

184. _____ grades wire are used in automatic re-threading mechanisms.

a) Malleable
b) Softer
c) Harder

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d) Commercial

Answer: c
Explanation: The harder grades are used in automatic re-threading mechanisms and also if
the machined shapes contain high flat surfaces. Hard wires resist change in direction and for
that reason are likely to produce nice flat surfaces.

185. For machining of high melting point materials, _____ wires are used.
a) gallium
b) zinc coated
c) aluminium coated
d) silver

Answer: b
Explanation: Zinc coated wire is used in machining high melting point workpiece materials.
The zinc coating vaporises in lower temperature than the brass core. Vaporisation reduces
the amount of heat that transmits to the brass and the core wears less.

186. _____ is/are used as di-electric fluid in die sink EDM process.
a) Pure water
b) Silicone gel
c) Petroleum products
d) Epoxy resins

Answer: c
Explanation: The dielectric fluid in the die-sink EDM process is usually some petroleum
product. In the wire cut EDM process, it is most common to use de-ionised water.

187. Which of the following is not the application of wire cut EDM process?
a) Machining ejector holes
b) Cutting the ejector pins
c) Machining cores of various moulds
d) Machining of complex shapes made of plastic

Answer: d
Explanation: The most typical wire cut EDM applications in mould making are: −
• Machining ejector holes
• Shaping and cutting the ejector pin ends to follow mould cavity surface shapes
• Machining cores and corresponding fastening holes in the mould plates and inserts.

188. During mould making by wire cut EDM, it is important to harden ______ to counter the
effects of changes in the shape of the workpiece due to heat treatment.
a) the insert
b) electrode wire
c) electrode holding coils
d) bolting points in the workpiece

Answer: a
Explanation: It is important to harden the insert or mould plate steel before making the tightly
tolerated ends in the ejector pin holes because the heat treatment tends to change the
workpiece shapes at a certain degree.

189. Which of the following machining process is usually preferred for cutting of ejectors
which are used in mould making?
a) Milling

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b) Hobbing
c) Wire-cut EDM
d) Die sink EDM

Answer: c
Explanation: There is a need to cut the ejector to a right dimension and if the cavity surface
is shaped there is also a need to shape the ejector end. The wire ED machine is one of the
most accurate machines in mould shops and usually there is also free machining time
available. Another option is to cut and shape the ejectors in a milling machine, but the most
accurate milling machines are used in mould cavity machining operations and normally they
are rather busy for long periods of time.

190. How many ways are there for making the fixed cores by wire cut EDM process?
a) 2
b) 3
c) 4
d) 5

Answer: a
Explanation: Basically there are two options for making the fixed cores:
− Machine the cores directly to the mould insert plate or mould plate
− Machine the cores to separate pieces of mould steel and attach the piece to the mould
assembly.

191. The selection of the manufacturing process depends upon ____________

a) chemical reactivity between the mould material and the di-electric fluid
b) mould shape
c) application of the mould
d) number of parts to be machined

Answer: b
Explanation: The selection depends on the core dimensions and shapes. High and narrow
cores or cores with sharp shapes are easiest to manufacture with separate parts. Special
cases are core pins. Core pins are used in making small diameter holes to castings.

192. The wire EDM process is used for making moulds with high drafted walls.
a) True
b) False

Answer: a
Explanation: Like every wall in the mould opening direction, the core walls are also drafted. It
is rather difficult to make high drafted walls with a milling machine. Especially in the case of
injection moulding or high pressure die casting moulds where the accuracy requirements are
very high. The wire ED machine produces these shapes accurately with ease.

193. For manufacturing of complex shapes, soft electrode wires are used.
a) True
b) False

Answer: a
Explanation: Soft wires are useful in applications with complex shapes, where the machine
changes the wire tilting angle several times. The harder grades are used in automatic re-
threading mechanisms

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Laser Beam Machining (LBM)

Laser Beam Machining-Introduction

194. What is the full form of LBM in advanced machining processes?
a) Laser Beam Manufacturing
b) Laser Beam Machining
c) Light Blast Manufacturing
d) Light Beam Machining

Answer: b
Explanation: The full form of LBM is Laser Beam Machining in the advanced machining
processes.

195. LBM offers a good solution for which material properties below?
a) Thermal conductivity
b) Specific heat
c) Boiling temperature
d) All of the mentioned

Answer: d
Explanation: LBM offers good solution for material properties such as thermal conductivity,
specific heat, melting and boiling temperatures.

196. What is the abbreviation of Laser?

a) Light allowed simple emission of radiation
b) Light amplification by stimulated emission of radiation
c) Light amplified simultaneous emission of rays
d) Light amplified stimulated emanation of rays

Answer: b
Explanation: Full form of laser is Light Amplification by Stimulated emission of radiation.

197. Which of the following are the properties of a laser?

a) Highly collimated
b) Monochromatic
c) Coherent light beam
d) All of the mentioned

Answer: d
Explanation: Highly collimated, high monochromaticity and the coherence of the light beam
are the properties of a laser.

198. Laser beam machining uses which type of power sources for machining?
a) Very low power
b) Low power
c) Medium power
d) High power

Answer: d
Explanation: High power densities are used for the generation of laser and for machining in
Laser beam machining.

199. Which of the following are different types of lasers used in Laser beam machining?
a) Solid-state ion

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b) Neutral gas
c) Semiconductor
d) All of the mentioned

Answer: d
Explanation: Laser such as solid-state ion, neutral gas, molecular, semiconductor etc.., can
be used in LBM.

200. Which types of lasers are used in Laser beam machining?

a) Continuous wave
b) Pulsed mode
c) Continuous wave & Pulsed mode
d) None of the mentioned

Answer: c
Explanation: Laser may be in continuous wave (CW) or in Pulsed mode (PM) for machining
in LBM.

201. What is the wavelength value of Ruby laser used in Laser beam machining?
a) 633 nm
b) 694 nm
c) 856 nm
d) 1064 nm

Answer: b
Explanation: The value of wave length of Ruby laser used in Laser Beam machining is 694
nm.

202. What is the wavelength value of Nd-YAG and Nd-glass lasers used in LBM?
a) 633 nm
b) 694 nm
c) 856 nm
d) 1064 nm

Answer: d
Explanation: The value of wave length of Nd-YAG and Nd-glass lasers used in LBM is 1064
nm.

203. What is the wavelength value of neutral gas laser used in LBM?
a) 633 nm
b) 694 nm
c) 856 nm
d) 1064 nm

Answer: a
Explanation: The value of wave length of Neutral gas laser used in Laser beam machining is
633 nm.

204. What is the wavelength value of CO2 laser used in Laser beam machining?
a) 0.16 μm
b) 1.6 μm
c) 10.6 μm
d) 106 μm

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Answer: c
Explanation: The value of wave length of CO2 laser used in Laser Beam machining is 10.6
μm.

205. What are the values of wavelengths of GaAs laser used in LBM?
a) 100 – 200 nm
b) 200 – 400 nm
c) 600 – 700 nm
d) 800 – 900 nm

Answer: d
Explanation: The wavelengths of GaAs laser used in LBM range from 800 – 900 nm.

206. What are the values of wavelengths of Excimer laser used in LBM?
a) 100 – 200 nm
b) 200 – 500 nm
c) 600 – 700 nm
d) 800 – 900 nm

Answer: b
Explanation: The wavelengths of Excimer laser used in LBM range from 200 – 500 nm.
14. What are the values of wavelengths of Argon laser used in LBM?
a) 120 – 230 nm
b) 220 – 310 nm
c) 330 – 530 nm
d) 760 – 940 nm

Answer: c
Explanation: The wavelengths of Argon laser used in LBM range from 330 – 530 nm

LBM-Material Removal
207. What is the material removal mechanism of Laser beam machining process?
a) Melt and evaporate
b) Electro chemical corrosion
c) Mechanical erosion of materials
d) Electro chemical dissolution

Answer: a
Explanation: The material is removed by melting and evaporation in Laser Beam Machining
process.

208. Physics of laser is very complex due to which of the reasons below?
a) Scattering loss
b) Reflection loss
c) Scattering & Reflection loss
d) None of the mentioned

Answer: c
Explanation: Physics of laser is very complex because of scattering and reflection losses.

209. What happens when the heat is diffused into bulk material?
a) Phase change occurs
b) Melting occurs
c) Vaporization may take place

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d) All of the mentioned

Answer: d
Explanation: The heat diffusion into bulk material causes phase change, melting or
vaporization in the materials.

210. State whether the following statement is true of false regarding LBM.
“In LBM, high intensity laser beams are recommended for more material.”
a) True
b) False

Answer: b
Explanation: High intensity laser beams are not recommended since they form a plasma
plume near surface of material.

211. What happens to the process efficiency if plasma plumes are formed in LBM?
a) Increases
b) Enhances
c) Decreases
d) Improves

Answer: c
Explanation: In Laser beam machining, the process efficiency is reduced due the absorption
and scattering loses when plasma plumes are formed.

212. Machining of LBM takes place when power density is ____________ than what is lost
by conduction and radiation.
a) Greater
b) Smaller
c) Lower
d) Same as

Answer: a
Explanation: Machining of laser takes place when power density is greater than what is lost
by conduction, convection and radiation.

213. Which of the following phenomenon take place before melting and evaporating in
LBM?
a) Conduction
b) Reflection
c) Absorption
d) All of the mentioned

Answer: d
Explanation: Material in LBM is removed through several effects such as conduction,
absorption, reflection following melting and evaporation.

214. What happens to the material removal rate when reflectivity is higher?
a) Will decrease
b) Will increase
c) Will enhance
d) Remains same

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Answer: a
Explanation: In LBM, as the reflectivity of the metals is increased the material removal rates
of the process are decreased.

215. Reflectivity of the materials depends on which of the following factors?

a) Wave length
b) Properties of material
c) Surface finish
d) All of the mentioned

Answer: d
Explanation: Reflectivity of the materials depends on wavelength, the properties of materials,
surface finish and temperature.

216. How much amount of incident radiation is reflected at lower power densities?
a) 10 percent
b) 20 percent
c) 50 percent
d) 90 percent

Answer: d
Explanation: Most of the metals reflect nearly 90 percent of incident radiation if the power
densities are low.

217. How are minimum energies required for plastics when compared to that required for
metals?
a) Lower than
b) Higher than
c) Same as
d) None of the mentioned

Answer: a
Explanation: The minimum energies required for plastic are lower than that required for
metals.

218. Which of the following has high machining speeds in Laser Beam Machining?
a) Metals
b) Non metals
c) Metal alloys
d) All of the mentioned

Answer: b
Explanation: Non metallic material machine at higher speeds than metallic ones due to
higher reflectivity in metallic materials

LBM-Applications
219. Which of the following are the applications of Laser Beam Machining?
a) Drilling
b) Cutting
c) Texturing
d) All of the mentioned

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Answer: d
Explanation: Drilling, cutting and grooving, texturing and structuring, milling and dressing
etc.., are the applications of Laser beam machining process.

220. State whether the following statement is true or false regarding the drilling using LBM.
“Compared to LBM, conventional machining is more accurate and efficient.”
a) True
b) False

Answer: b
Explanation: Conventional machining is less sufficient than Laser Beam machining because
of their material toughness.

221. Other non-conventional processes lay behind Laser beam machining in drilling
process because of which factors below?
a) High cost
b) Long lead times
c) Low machining speeds
d) All of the mentioned

Answer: d
Explanation: Other non-conventional processes need high costs for tools, long lead times,
and low machining speeds when compared to LBM.

222. Laser drilling has proven to be more efficient in which of the following factors?
a) Cost
b) Quality
c) Reliability
d) All of the mentioned

Answer: d
Explanation: Laser drilling has proven to be an efficient one in terms of cost, quality, and
reliability for large-scale production applications.

223. Which of the following are different laser drilling processes in Laser beam machining?
a) Direct drilling
b) Drill and ream
c) Trepanning
d) All of the mentioned

Answer: d
Explanation: Laser drilling can be performed by three methods that are – direct (percussion)
drilling, trepanning, drill and ream.

224. The hole size in direct drilling depend up on which of the factors below?
a) Input power
b) Focusing adjustments
c) Input power & Focusing adjustments
d) None of the mentioned

Answer: c
Explanation: The hole size in the direct drilling method of Laser drilling process, depend on
input power and focusing adjustments.

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225. Which method mentioned below is used for drilling of large size holes?
a) Direct drilling
b) Drill and ream
c) Trepanning
d) All of the mentioned

Answer: c
Explanation: Trepanning method of laser drilling process is used for drilling large holes either
by rotating or moving the part.

226. What are the values of diameters obtained by using Laser drilling process?
a) 0.0001 – 0.001 mm
b) 0.001 – 0.01 mm
c) 0.005 – 1.25 mm
d) 1.5 – 10.5 mm

Answer: c
Explanation: Values of diameters obtained by using Laser drilling process range between
0.005 – 1.27 mm.

227. What is the value the maximum optimum depth that can be machined using Laser
drilling process?
a) 0.17 mm
b) 1.7 mm
c) 17.1 mm
d) 171.7 mm

Answer: b
Explanation: The maximum depth obtained when by using laser drilling is about 1.7 mm.

228. What are the values of entrance angles that vary in Laser drilling process?
a) 0.1 – 1 oC
b) 1 – 5 oC
c) 15 – 90 oC
d) 90 – 150 oC

Answer: c
Explanation: Values of the entrance angles in Laser drilling process range between 15 –
90 oC.

229. The taper obtained in Laser drilling process is how much of the hole diameter?
a) 1 – 5%
b) 5 – 20%
c) 20 – 50%
d) 50 – 90%

Answer: b
Explanation: Taper value obtained in Laser drilling process range between 5 – 20% of the
hole diameter.

230. What is the depth-to-diameter ratio obtained in drilling process using Laser beam
machining?
a) 10:1
b) 20:1
c) 50:1

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d) 80:1

Answer: c
Explanation: Value of the maximum depth-to-diameter ratio obtained in drilling using Laser
beam machining is 50:1.

231. What is the maximum value of drilling depth in trepanning method of laser drilling
process?
a) 1.7 mm
b) 4.3 mm
c) 6.4 mm
d) 7.9 mm

Answer: c
Explanation: The depth increases when we use a trepanning method for laser drilling
process and that is about 6.40 mm.

232. What are the tolerance values obtained when we use laser drilling process?
a) 0.1 – 5%
b) 5 – 20%
c) 25 – 50%
d) 50 – 80%

Answer: b
Explanation: The tolerance values are will range between 5 – 20% of the diameters obtained
in Laser drilling process.

233. What is the value of minimum corner radius obtained by drilling in Laser beam
machining?
a) 0.10 mm
b) 0.25 mm
c) 0.50 mm
d) 0.65 mm

Answer: b
Explanation: The value of the minimum corner radius obtained while drilling using LBM is
about 0.25 mm

234. Peak power should be increased in Laser drilling process by __________ pulse
energy.
a) Increasing
b) Decreasing
c) Reducing
d) Constant

Answer: a
Explanation: Required peak power in the laser drilling process can be obtained by increasing
the pulse energy while keeping the pulse duration constant.

235. Drilling of holes with larger pulse duration causes which effect to the holes produced?
a) Enlarge holes
b) Reduce hole size
c) Decrease the depth
d) All of the mentioned

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Answer: a
Explanation: Drilling the holes with larger pulse duration causes enlargement of the hole
entrance.

236. What are pulse duration values used for laser drilling?
a) 0.01 to 0.25 ms
b) 0.1 to 2.5 ms
c) 1 to 25 ms
d) 10 to 250 ms

Answer: b
Explanation: Value of the duration of the pulse range from 0.1 to 2.5 ms.

237. _________ pulse energy and _________ pulse duration are suitable for drilling.
a) Low, short
b) Low, long
c) High, short
d) High, long

Answer: c
Explanation: In LBM, high energy pulses and low pulse duration are more suitable for hole
drilling in aerospace materials.

238. Which of the following are the functions of assist gases?

a) Removal of molten material
b) Shield the lenses
c) Better efficiency
d) All of the mentioned

Answer: d
Explanation: Assist are used to remove the molten material, it also shield the lenses from
expelled material and they are also used for obtaining better process efficiencies.

239. Selection of assist gas depends on which of the following properties of work piece?
a) Material
b) Thickness
c) Material & Thickness
d) None of the mentioned

Answer: c
Explanation: The selection of different assist gases depends on the work piece material and
its thickness.

240. Which of the following properties of material affect the quality of holes obtained?
a) Reflectivity
b) Absorption coefficient
c) Thermal conductivity
d) All of the mentioned

Answer: d
Explanation: Quality of holes depend on reflectivity, absorption coefficient, thermal
conductivity, density, specific heat, and latent heat of material.

241. What range of powers are used for cutting through steel?
a) 1 to 20 W

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b) 20 to 100 W
c) 200 to 1000 W
d) 1 to 20 kW

Answer: c
Explanation: The power ranges from 200 W to 1 kW for cutting through steel.

242. Which gas jet assisted process is suitable for most of the metals?
a) Oxygen gas
b) Nitrogen gas
c) Helium gas
d) All of the mentioned

Answer: a
Explanation: Oxygen-jet assistance is used for most metals, as the gas liberates additional
energy by the exothermal chemical reactions.

243. What happens to the cutting speed with an increase in the work piece?
a) Increases
b) Decreases
c) Enhances
d) Remains same

Answer: b
Explanation: The cutting speed of the process of drilling decreases with an increase in the
thickness of the work piece material.

244. What is the full form of LBT in the processes of LBM?

a) Laser Beam Tempering
b) Laser Beam Templating
c) Laser Beam Texturing
d) Laser Beam Tinning

Answer: c
Explanation: Full form of LBT is Laser beam texturing which is an application of Laser beam
machining.

245. Depth and the crater size depends on which of them below?
a) Energy of beam
b) Dwell time of beam
c) Energy & Dwell time of beam
d) None of the mentioned

Answer: c
Explanation: Depth and the crater size depend on the energy and the dwell time of beam.

246. Where are the textured surfaces used that are obtained in LBT?
a) Mould makings
b) Bearings
c) Printer roll manufacturing
d) All of the mentioned

Answer: d
Explanation: Textured surfaces obtained in LBT are widely used in mold making, bearings
and printer roll manufacturing.

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247. The roll is _________ and the laser beam is moved ________ along the roll.
a) Stationary, axially
b) Stationary, perpendicularly
c) Rotated, axially
d) Rotated, perpendicularly

Answer: c
Explanation: In texturing process of LBT, the roll is rotated and laser is moved axially along
the roll.

248. State whether the following statement is true regarding the texturing in LBT.
“In LBT, hardness of the material is a limitation to the process.”
a) True
b) False

Answer: b
Explanation: In Laser beam texturing, hardness of material is not a limitation to the process

249. Which of the following are the other applications of LBM?

a) Dressing of grinding wheels
b) Scribing
c) Micromachining
d) All of the mentioned

Answer: d
Explanation: Dressing of grinding wheels, scribing, micromachining, controlled fracturing are
some of the other applications of Laser beam machining.

250. How the grooves in grinding wheels are produced using laser?
a) Evaporation
b) Damage of composite
c) Evaporation & Damage of composite
d) None of the mentioned

Answer: c
Explanation: Grooves on the grinding wheels are produced due to evaporation and damage
of the composite wheel material.

251. Work piece tilting depends on which of the following factors?

a) Incident power
b) Beam speed
c) Groove direction
d) All of the mentioned

Answer: d
Explanation: Work piece tilting depends on the incident power, beam speed, groove
direction, and optical absorption coefficient of the material.

252. What are the values of thickness used is fine cutting process?
a) 0.01 to 0.05 mm
b) 0.05 to 0.1 mm
c) 0.5 to 15 mm
d) 15 to 50 mm

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Answer: c
Explanation: The thickness of material used in fine cutting process vary from 0.5 to 16 mm.

253. The advantages of excimer laser are due to __________ laser wavelength and
_________ pulse duration.
a) Short, short
b) Short, long
c) Long, short
d) Long, long

Answer: a
Explanation: The practical advantages of excimer laser are mainly due to short laser
wavelength and pulse duration.

254. Lasers of which type are used for modification of electronic components?
a) High power
b) Small spot size
c) Short pulse length
d) All of the mentioned

Answer: d
Explanation: Lasers of high power density, small spot size and short pulse length are useful
devices for modification of electronic components.

255. Material removal rates which are about mg/pulse produces which type of holes?
a) Shallow
b) Deep
c) Very deep
d) All of the mentioned

Answer: a
Explanation: In LBM, material removal at the rate of milligrams per pulse produces shallow
holes in the material.

256. Which of the following materials can be easily separated by laser scribing?
a) Silicon
b) Glass
c) Ceramic
d) All of the mentioned

Answer: d
Explanation: Brittle materials such as silicon, glass and ceramics may be effectively shaped
or separated by laser scribing.

257. Which type of holes can be drilled using Nd-YAG laser?

a) Small holes
b) Large holes
c) Small & Large holes
d) None of the mentioned

Answer: c
Explanation: Nd-YAG laser can be used for drilling small holes as well as large holes by
trepanning process.

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258. Which type of laser can be used for direct drilling or percussion?
a) Ruby laser
b) Nd-YAG laser
c) Ruby & Nd-YAG laser
d) None of the mentioned

Answer: c
Explanation: Both Ruby and Nd-YAG laser can be used for direct (percussion) drilling
purpose.

259. Which of the following lasers is used for cutting thick materials in LBM?
a) CO2 + gas assisted
b) CO2 only
c) Nd-YAG
d) Ruby

Answer: a
Explanation: CO2 + gas assisted laser is used for cutting thicker materials in Laser beam
machining process.

260. Which of the following lasers is used for slitting of thin metallic materials in LBM?
a) CO2 + gas assisted
b) CO2 only
c) Nd-YAG
d) Ruby

Answer: c
Explanation: Nd-YAG laser is used for slitting of thin metallic materials in Laser beam
machining process.

261. Which of the following lasers is used for slitting of thin plastic materials in LBM?
a) CO2 + gas assisted
b) CO2 only
c) Nd-YAG
d) Ruby

Answer: b
Explanation: CO2 laser is used for slitting of thin plastic materials in Laser beam machining
process.

262. Which of the following lasers is used for organics and non-metallic materials in LBM?
a) CO2 + gas assisted
b) Pulsed CO2
c) Nd-YAG
d) Ruby

Answer: b
Explanation: Pulsed CO2 laser is used for organics and non-metallic materials in Laser beam
machining process.

263. Which of the following lasers is used for ceramic materials in LBM?
a) Pulsed CO2
b) Nd-YAG
c) Pulsed CO2 & Nd-YAG

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d) None of the mentioned

Answer: c
Explanation: Both pulsed CO2 and Nd-YAG lasers can be used for ceramic materials in LBM

LBM-Advantages and Limitations

264. Which of the following is not an advantage of LBM?
a) Rapid machining
b) Low operating cost
c) High equipment cost
d) No tool wear

Answer: c
Explanation: Rapid machining, low operating cost and no tool wear are some of the
advantages of Laser beam machining.

265. Which of the following systems is used for locating the hole accurately for alignment?
a) Mechanical control system
b) Optical laser system
c) Measurement system
d) Alignment system

Answer: b
Explanation: Holes can be accurately located using optical laser system for alignment in
Laser beam machining.

266. Very __________ holes with a ________ aspect ratio can be produced using Laser
beam machining.
a) Small, small
b) Small, large
c) Large, small
d) Large, large

Answer: b
Explanation: In Laser beam machining, very small holes with large aspect ratios can be
produced.

267. How are the machining times in Laser beam machining?

a) Very slow machining times
b) Slow machining times
c) Moderate machining times
d) Fast machining times

Answer: d
Explanation: Machining is very much rapid and the setup times are economical in Laser
beam machining.

268. How is the operating cost of the machines used in Laser beam machining?
a) Low
b) Moderate
c) High
d) Very high

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Answer: a
Explanation: The operating cost of the machines in LBM is low but the equipment cost itself
is of high cost.

269. State whether the following statement is true or false regarding the advantages of
LBM.
“In LBM, difficult to cut machine material can also be machined.”
a) True
b) False

Answer: a
Explanation: A large variety of hard and difficult to cut materials can be machined using
LBM.

270. How much amount of tapers are occurred in Laser drilled holes?
a) No taper
b) Negligible amount of taper
c) Some amount
d) None of the mentioned

Answer: c
Explanation: Tapers are generally occurred in the direct drilling of holes using Laser beam
machining.

271. State whether the following statement regarding Laser beam machining is true or false.
“In LBM, a blind hole of precise depth is easy to achieve.”
a) True
b) False

Answer: b
Explanation: A blind hole of precise is difficult to achieve in Laser beam machining.

272. What is the maximum depth up to which holes can be drilled using LBM?
a) 10 mm
b) 30 mm
c) 50 mm
d) 70 mm

Answer: c
Explanation: The thickness of the material that can be laser drilled is restricted to 50 mm.

273. What is to be done to the adherent material which are found at exit holes?
a) Shape them
b) Leave away
c) Remove them
d) Flatten them
View Answer
Answer: c
Explanation: Adherent material found at the exit of holes has to be removed in LBM

Plasma Arc Machining (PAM) / Plasma Beam Machining

Plasma Beam Machining-Introduction And Machining system

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274. What is the full form of PBM in the advanced machining processes?
a) Plasma Beam Manufacturing
b) Plasma Beam Machining
c) Plasma Blast Manufacturing
d) Plasma Blast Machining

Answer: b
Explanation: The full form of PBM in the advanced machining processes is Plasma Beam
Machining.

275. When the Plasma Beam machining process came into the industrial world?
a) 1920s
b) 1930s
c) 1950s
d) 1970s

Answer: c
Explanation: The Plasma Beam machining process came into the industrial world in the early
1950s as an alternative for the oxy-gas flame cutting process.

276. PBM is the only process which works faster in ________ steel than _________ steel.
a) Stainless, mild
b) Mild, stainless
c) Remains same all
d) All of the mentioned

Answer: a
Explanation: PBM is the only fabrication process which works faster in stainless steels
compared to mild steels.

277. What is the temperature reached by cathode in order to produce plasma beam?
a) 12000 ºC
b) 18000 ºC
c) 28000 ºC
d) 40000 ºC

Answer: c
Explanation: The temperature reached by cathode to produce plasma arc is about 28000 ºC
in Plasma Beam Machining.

278. What is the value of velocity of plasma jet in Plasma beam machining?
a) 100 m/sec
b) 300 m/sec
c) 400 m/sec
d) 500 m/sec

Answer: d
Explanation: The value of the velocity of the plasma jet in Plasma beam machining is about
500 m/sec.

279. What is the value of material removal rate in Plasma Beam Machining process?
a) 50 cm3/min
b) 100 cm3/min
c) 150 cm3/min

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d) 200 cm3/min

Answer: c
Explanation: The values of the material removal rates in Plasma beam machining will be
nearly 150 cm3/min.

280. What is the value of specific energy used in Plasma beam machining process?
a) 100 W/(cm3-min)
b) 200 W/(cm3-min)
c) 300 W/(cm3-min)
d) 400 W/(cm3-min)

Answer: a
Explanation: The value of the specific energy used in Plasma beam machining process is
about 100 W/(cm3-min).

281. What is the value of the power used in PBM process?

a) 0.1 – 10 kW
b) 2 – 200 kW
c) 200 – 400 kW
d) 400 – 700 kW

Answer: b
Explanation: The value of the power used in Plasma beam machining range from 2 to 200
kW.

282. What is the value of the voltage used in PBM process?

a) 0.1 – 20 V
b) 30 – 250 V
c) 300 – 400 V
d) 500 – 600 V

Answer: b
Explanation: The value of voltage in the Plasma beam machining processes is about 30 –
250 V.

283. What is the value of the current used in PBM process?

a) Up to 200 A
b) Up to 400 A
c) Up to 600 A
d) Up to 800 A

Answer: c
Explanation: The value of the current used in PBM will be up to 600 A.

284. What is the value of machining speed used in PBM process?

a) 0.1 – 7.5 m/min
b) 8.5 – 10.5 m/min
c) 15.5 – 19.5 m/min
d) 20.5 – 25.5 m/min

Answer: a
Explanation: The value of machining speed is about 0.1 – 7.5 m/min in Plasma beam
machining process.

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285. What is the maximum value of the thickness used in PBM process?
a) 100 mm
b) 200 mm
c) 300 mm
d) 400 mm

Answer: b
Explanation: The maximum value of the thickness used in the Plasma beam machining
process is about 200 mm.

286. Which of the following are the different shielded plasmas used in PBM?
a) Gas-shielded plasma
b) Water-shielded plasma
c) Gas-shielded & Water-shielded plasma
d) None of the mentioned

Answer: c
Explanation: Both gas-shielded plasma and water shielded plasma are used in the Plasma
beam machining process

PBM – MRR, Surface Quality, Applications, Advantages and

Disadvantages
287. Material removal rates depend on which of the following factors?
a) Work piece material
b) Type of cutting
c) Shielding gases
d) All of the mentioned

Answer: d
Explanation: Material removal rates in PBM depend on work piece material, type of cutting
and the shielding gas.

288. A low power factors indicates __________ energy required and __________ removal
rates.
a) Low, low
b) Low, high
c) High, low
d) High, high

Answer: b
Explanation: A low power factor in Plasma beam machining indicates low energy required
and high material removal rates.

289. What happens to the machining speed if the thickness of material is increased in
PBM?
a) Decreases
b) Increases
c) Enhanced
d) Remains same

Answer: a
Explanation: Machining speed in Plasma beam machining reduces with an increase in the
thickness of the work piece material.

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290. What is the machining speed required for machining of 12mm thick plate with 220 kW
energy?
a) 1000 mm/min
b) 1500 mm/min
c) 2000 mm/min
d) 2500mm/min

Answer: d
Explanation: Machining speed required for cutting 12-mm thick plate with 220 kW power is
about 2500 mm/min.

291. How much distortion is produced while machining using PBM?

a) 10%
b) 20%
c) 30%
d) No distortion is produced

Answer: d
Explanation: Heat does not penetrate more than few microns from the edges of the cuts
produced by machining using PBM that produce no distortion.

292. The cut edge of the material tends to be __________ than the base metal in PBM.
a) Smoother
b) Harder
c) Same as
d) None of the mentioned

Answer: b
Explanation: The cut edge of material in PBM tends to be harder than the base metal.

293. What is the thickness of the HAZ in PBM?

a) 0.001 to 0.23 mm
b) 0.25 to 1.12 mm
c) 1.3 to 2.56 mm
d) 2.73 to 5.26 mm

Answer: b
Explanation: The thickness of the HAZ obtained in PBM range from 0.25 to 1.12 mm.

294. How much thickness of cracks may arise beyond HAZ due to rapid cooling?
a) 1.6 mm
b) 2.6 mm
c) 3.6 mm
d) 4.6 mm

Answer: a
Explanation: The cracks due to rapid cooling in PBM may extend beyond HAZ to a thickness
of 1.6 mm.

295. What are the values of tolerances obtained by using PBM?

a) ± 0.6 mm
b) ± 1.6 mm
c) ± 2.6 mm
d) ± 3.6 mm

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Answer: b
Explanation: The values of the tolerances obtained by using Plasma beam machining will be
about ± 1.6 mm.

296. What is the maximum thickness of the walls of tube machined using plasma arc?
a) 10 mm
b) 30 mm
c) 50 mm
d) 70 mm

Answer: c
Explanation: The maximum thickness of the wall tubes that can be produced using PBM is
about 50 mm.

297. Which of the following are the advantages of PBM?

a) No chemical
b) Less harmful
c) Operates cleanly
d) All of the mentioned

Answer: d
Explanation: Main advantages of Plasma bema machining are no complicated chemical
analysis, less harmful and no harmful exposure and it operates cleanly.

298. Which of the following chemicals are used in PBM?

a) Harmful chlorinated fluorocarbons
b) Acid cleaning chemicals
c) Dissolvable solvent chemicals
d) None of the mentioned

Answer: d
Explanation: Plasma beam machining uses no harmful chlorinated fluorocarbons, acid
cleaning chemicals or any dissolvable solvents.

299. How much amount of energy is required for machining using PBM?
a) Low
b) Moderate
c) High
d) Very high

Answer: a
Explanation: The cost for operating the jobs in Plasma beam machining is less and also less
energy is required for operating the machine in PBM.

300. What are the disadvantages of PBM?

a) Large power supplies
b) Heat produced
c) Toxic fumes produced
d) All of the mentioned

Answer: d
Explanation: Large power for more thick materials, production of heat and toxic fumes are
some of the main disadvantages of PBM

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Electron Beam Machining (EBM)

Electron Beam Machining-Introduction, Equipment and Material

removal
301. What is the full form of EBM in the advanced machining processes?
a) Electro blast manufacturing
b) Electron beam machining
c) Electron beam manufacturing
d) Electron blast manufacturing

Answer: b
Explanation: The full form of EBM is Electron beam machining in the advanced machining
processes.

302. The prototype of the machine used in EBM process was first introduced in which year?
a) 1924
b) 1943
c) 1947
d) 1956

Answer: c
Explanation: Steigerwald was the scientist who designed a prototype machine of electron
beam machining in 1947.

303. When did the Electron beam machining come into the machining industry?
a) 1920s
b) 1930s
c) 1950s
d) 1960s

Answer: d
Explanation: The Electron beam machining was introduced to the machining industry in the
early 1960s.

304. Which of the following are the applications of EBM process?

a) Drilling
b) Cutting
c) Engraving
d) All of the mentioned

Answer: d
Explanation: Drilling small holes, cutting, engraving, and heat treatment are some of modern
applications of Electron beam machining.

305. The tungsten filament cathode is heated to what temperatures in EBM?

a) 1000 to 1500 ᵒC
b) 1500 to 2000 ᵒC
c) 2500 to 3000 ᵒC
d) 3500 to 5000 ᵒC

Answer: c
Explanation: The tungsten filament cathode is heated to 2500 to 3000 ᵒC in Electron beam
machining.

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306. What are the values of currents used in EBM process?

a) 1 and 20 mA
b) 20 and 100 mA
c) 100 and 200 mA
d) 200 and 400 mA

Answer: b
Explanation: The values of the currents used in the Electron beam machining process are
between 20 and 100 mA.

307. What are the values of current densities used in the process of EBM?
a) 5 and 15 A/cm2
b) 15 and 20 A/cm2
c) 20 and 30 A/cm2
d) 40 and 60 A/cm2

Answer: a
Explanation: The values of the current densities used in EBM lie between 5 and 15 A/cm 2.

308. Emission current depends up on which of the following factors?

a) Cathode material
b) Temperature
c) Voltage supply
d) All of the mentioned

Answer: d
Explanation: Emission current depends on the cathode material, temperature, and the high
voltage in the process of Electron beam machining.

309. What are the values of voltages used in the EBM process?
a) 10 V
b) 50 V
c) 150 V
d) 200 V

Answer: c
Explanation: The values of voltages used in the process of electron beam machining is
about 150 V.

310. Which of the following lenses are used for refocussing the electrons in EBM process?
a) Magnetic lens
b) Electronic lens
c) Magnetic & Electronic lens
d) None of the mentioned

Answer: c
Explanation: Magnetic and electronic lenses are used to refocus the electrons in EBM
process.

311. What are the values of velocity maintained in the EBM process?
a) 118 x 103 m/s
b) 228 x 103 m/s
c) 338 x 103 m/s
d) 448 x 103 m/s

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Answer: b
Explanation: The value of the velocity used in the process of electron beam machining is
about 228 x 103 m/s.

312. What are the values of power densities used in the EBM process?
a) 0.05 MW/mm2
b) 0.55 MW/mm2
c) 1.55 MW/mm2
d) 2.55 MW/mm2

Answer: c
Explanation: The value of the power densities used in the process of electron beam
machining are about 1.55 MW/mm2.

313. What is the frequency of the pulse of electrons used in EBM process?
a) 10 Hz
b) 102 Hz
c) 103 Hz
d) 104 Hz

Answer: d
Explanation: A pulsed electron beam at 104 Hz reduces the temperature of the work piece
outside the region being machined.

314. What are the values of material removal rates in EBM process?
a) 1 mm3/min
b) 10 mm3/min
c) 100 mm3/min
d) 1000 mm3/min

Answer: b
Explanation: The values of the material removal rates in the process of electron beam
machining are about 10 mm3/min.
15. What are the values of the cavity diameters that are obtained in EBM?
a) 15 to 20 µm
b) 20 to 25 µm
c) 30 to 35 µm
d) 35 to 40 µm

Answer: d
Explanation: The values of the cavity diameters range from 35 to 40 µm

EBM-Applications, Advantages and Disadvantages

315. Which of the following are the applications of EBM?
a) Hole drilling
b) Slotting
c) Perforation of thin sheets
d) All of the mentioned

Answer: d
Explanation: Drilling, perforation of thin sheets, slotting and integrated circuit fabrication are
some of the applications of Electron beam machining.

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316. What is the value of largest diameter of the hole drilled on EBM?
a) 0.5 mm
b) 1.0 mm
c) 1.5 mm
d) 2.0 mm

Answer: c
Explanation: The maximum value of diameter that can be drilled using Electron beam
machining is about 1.5 mm.

317. What is the value of maximum depth of the hole drilled on EBM?
a) 10 mm
b) 20 mm
c) 30 mm
d) 40 mm

Answer: c
Explanation: Value of the maximum depth that can be drilled using Electron beam machining
is about 10 mm.

318. What is the range of depth-to-diameter ratio in Electron beam machining?

a) 2:5 to 2:11
b) 1:1 to 1:15
c) 3:4 to 3:20
d) 4:5 to 4:19

Answer: b
Explanation: The depth to diameter ratio in Electron beam machining will vary between 1:1
and 1:15.

319. How many holes can be produced in perforation of thin sheets using EBM?
a) 101 to 102
b) 102 to 103
c) 103 to 104
d) 104 to 105

Answer: d
Explanation: Number of holes produced range from 10 4 to 105 per second in perforation
using EBM.

320. What is the value of energy required for bond breaking?

a) 10 to 20kV
b) 20 to 30kV
c) 30 to 40kV
d) 40 to 50kV

Answer: a
Explanation: Value of the beam energy used for breaking bonds or cross linking them range
from 10 to 20kV.

321. What is the value of pulse time used in EBM?

a) 0.004 to 0.064 µs
b) 0.04 to 0.64 µs
c) 0.4 to 640 µs

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d) 4 to 64000 µs

Answer: d
Explanation: Value of the pulse time of beam ranges from 4 to 64000 µs.

322. What is the value of frequency used in EBM?

a) 0.001 – 0.016 Hz
b) 0.01 – 16 Hz
c) 0.1 – 16000 Hz
d) 10 – 1600 kHz

Answer: c
Explanation: The frequency of the pulse range between 0.1 and 16000 Hz in Electron beam
machining.

323. What is the tolerance value obtained in EBM?

a) ± 10 %
b) ± 20 %
c) ± 30 %
d) ± 40 %

Answer: a
Explanation: The tolerances obtained in Electron beam machining is about ± 10 % of the
depth of cut.

324. Which of the following are the advantages of EBM process?

a) Drilling rates
b) No distortion
c) High accuracy
d) All of the mentioned

Answer: d
Explanation: The main advantages of Electron beam machining are high drilling rates, no
mechanical distortion, high accuracy and repeatability.

325. There is no limitation imposed on which of the following factors in EBM?

a) Material ductility
b) Surface hardness
c) Surface reflectivity
d) All of the mentioned

Answer: d
Explanation: In Electron beam machining, no limitation is imposed by work piece hardness,
ductility, and surface reflectivity.

326. How much is the capital equipment cost of equipment used in EBM?
a) Very low cost
b) Low cost
c) Moderate cost
d) High cost

Answer: d
Explanation: The capital equipment cost of the Electron beam machining is high compared
to other machining processes.

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327. How are the production times for a material in electron beam machining?
a) Very small
b) Small
c) Moderate
d) Long

Answer: d
Explanation: In Electron beam machining, long production times are required due to the
generation of vacuum in the chamber for machining purpose.

328. Which type of thin cast layer is produced when we use EBM?
a) Thin layer
b) Thick layer
c) No layer
d) All of the mentioned

Answer: a
Explanation: Thin recast layer is produced in Electron beam machining which an added
disadvantage to the machining process

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