Multiple Choice Questions: Subject: Advanced Manufacturing Processes Unit 1: Special Forming Processes
Multiple Choice Questions: Subject: Advanced Manufacturing Processes Unit 1: Special Forming Processes
Multiple Choice Questions: Subject: Advanced Manufacturing Processes Unit 1: Special Forming Processes
Answer: c
Explanation: Roll forming is a continuous process for forming sheet, strip or coiled metal stock into
long shapes of essentially uniform cross-section. The material is fed through pairs of contoured
forming rolls, which progressively shape the metal until the desired cross-section is produced.
2. Which of the following are the most desirable materials used in roll forming?
a) Spring steel b) Chromium-molybdenum steel c) Non-metals d) Mild steels and aluminium
Answer: d
Explanation: Both ferrous and non-ferrous metals as well as some non-metallic material can be roll
formed. Mild steel and aluminium are the most common materials used in the process. Additionally,
polished, painted, coated and plated materials can also be roll formed.
Answer:d
Explanation: The stock to be roll formed may be either pre-cut to a pre-determined length before roll
forming, or post-cut afterward to a specified dimension. But the latter one is the most common. By
incorporating auxiliary equipment such as pre-notching, punching, embossing, etc. the post-cut
method can be a complete net-shape process, fully automated.
9. Which of the following is the most common material used to produce forming rolls?
a) Aluminium b) Carbide c) Chrome steels d) Oil hardened tool steels
Answer:d
Explanation: Several types of materials are used in the manufacture of the forming rolls and oil
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hardened tool steel being the most common. For extended tool life, hardened high-carbon, high-
chromium too steels are used. On extremely tough forming applications involving high temperatures
and or abrasive materials, aluminium/bronze or carbide rolls are required.
10. Which of the following is used for lubrication in heavy-duty roll forming?
a) Extreme pressure-type solutions b) Soap-type solutions
c) Non-ionic type solutions d) Micro-emulsions
Answer: b
Explanation: The soap-type solutions are used for heavy-duty roll forming. Non-ionic type solutions
are excellent for roll forming aluminium and coated components and extreme pressure-type are used
for high strength alloys.
Ans:-b
Ans:-a
Ans:- a
14. In HREF dies need to be much bigger to withstand high energy rates and shocks and to
prevent .
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a)Deformation b)Elongation c)Cracking d)Bulk
Ans:-c
Ans:-e
Ans:- c)
17. In uncofined type explosive forming the is necessary in the die to prevent
adiabatic heating of the work which may lead to oxidation or melting.
a)water b)air c)vacuum d)explosive
Ans:- c.
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Ans:-a
Ans:-b
21. In electromagnetic forming, coil is firmly held and hence the work piece collapses into the
die cavity due to . thus assuming die shape.
a.air gap b)vacuum c)current d)magnetic repelling force
Ans:-d
Ans:-d
23. What is (are) the limitation(s) of electromagnetic forming.
a) Applicable only for electrically conducting materials. b) Not suitable for large work pieces.
c) Rigid clamping of primary coil is critical. d)All of these.
Ans:-d
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25. The following Image related to forming processes.
26. Which of the following is Not the type of Bulk forming processes.
a)Wire Drawing b)Bending c)Rolling d)Forging
Ans:-b
27. Which of the following is Not the type of Sheet Metal forming processes.
a)Bending b)Deep Drawing c)Shearing d)Extrusion
Ans:-d
28. Which of the following is Not the type of HREF processes.
a)Electromagnetic Forming b)Explosive forming c)Electro hydraulic d)Forge forming Ans:-
d
29. . The following Image related to forming processes.
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32. The following figure related to forming process.
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Ans:-c
40. The following figure related to process.
a)Sheet metal Spinning b) Forward Flow forming c)Backward Flow forming d)Roll forming
Ans:-b.
41. In proess, it does not required lubrication.
a) Stretch b)roll c)Shear flow d)Incremental Shear
Ans:-a
42. The process is also known as single point forming.
a) Stretch forming b)roll process forming c)Shear flow process forming
d)Incremental Shear forming Ans:-d
43. The following figure related to forming process.
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Ans:-a
46. The following figure related to process.
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Academic Year 2019-20
Answer: c
Explanation: Friction Welding (FRW) is a solid state welding process which produces welds
due to the compressive force contact of work pieces which are either rotating or moving relative
to one another.
a) elastic deformation
b) plastic deformation
c) ductile deformation
d) brittle deformation
Answer: b
Explanation: In friction welding the heat required to produce the joint is generated by friction heating at
the interface. This heat displaces material plastically from the faying surfaces.
Answer: d
Explanation: A low contact pressure may be applied initially to permit cleaning of the surfaces
by a burnishing action. This pressure is then increased and contacting friction quickly generates
enough heat to raise the abutting surfaces to the welding temperature.
Answer: a
Explanation: As soon as the welding temperature is reached, rotation is stopped and the pressure is
maintained or increased to complete the weld. The softened material is squeezed out to form a flash. If
desired, the flash can be removed by subsequent machining action.
Answer: c
Explanation: During friction welding, a forged structure is formed in the joint. Friction welding
has been used to join steel bars upto 100 mms in diameter and tubes with outer diameter upto
100 mm.
Answer: a
Explanation: Inertia welding is a modified form of friction welding, where the moving piece is attached
to a rotating flywheel. The flywheel is brought to a specified rotational speed and is then separated from
the driving motor.
Answer: b
Explanation: The weld is formed when the flywheel stops its motion and the pieces remain
pressed together. Since the conditions of the inertia welding are easily duplicated, welds of
consistent quality can be produced and the process can be easily automated.
Answer: d
Explanation: Dry bearing and non-forgeable materials cannot be welded by a friction welding
process, i.e., one of the components must be ductile when hot, to permit deformations.
Preparation and alignment of the workpieces of the workpieces may be critical for developing
for developing uniform rubbing and heating, particularly for pieces having diameters larger
than 50mm.
Answer: c
Explanation: The basic problems with friction welding of aluminium and its alloys are that they
possess:
Cast brittle dendritic structure
Micro porosity
Loss of strength in heat affected zone
11. Which of the following processes can be used as alternative technique for joining
aluminium and its alloys?
a) Tungsten inert-gas welding
b) Metal inert-gas welding
c) Friction stir welding
d) Oxy-Acetylene flame technique
Answer: c
Explanation: The following alternate techniques are being used for joining of aluminium and its
alloys:
• Electron beam welding
• Laser beam welding
• Variable polarity plasma arc welding
• Friction stir welding.
12. All metallic engineering materials which are can be friction welded.
a) soft
b) weldable
c) forgeable
d) metamaterials
Answer: c
Explanation: As a rule, all metallic engineering materials which are forgeable can be friction
welded, including automotive valve alloys, maraging steel, tool steel, alloy steels and tantalum.
In addition, many castings, powder metals and metal matrix composites are weldable.
Answer: c
Explanation: Friction welding produces forged quality joints, with a 100% butt joint weld
through the contact area. Furthermore, in friction welding heat affected zone is much narrower
as compared to other welds, which indeed reduces the cost of post-weld heat treatments (stress
relieving processes).
b) Molten metal
c) Flash curl
d) Fly ash
Answer: c
Explanation: The flash curl generated during welding is coherent, will not flake off, and can
often be left intact if design and engineering considerations allow. Alternately, parts can
frequently be designed to accommodate the flash curl in a recess (flash trap).
Answer: c
Explanation: The advantages of this process such as no smoke, fumes or gases, or few sparks
produced, and the fact that the process is machine-controlled, make it suitable for use in
potentially explosive or hazardous environments. The machine can be fully automated so the
operator can be safely located out of harm’s way. This process is not applicable to non-
forgeable metals.
16.From given below which one is not the processes parameter of FSW.
17.In FSW small change in shape of tool can cause significance change in and
quality of weld.
19. is the constant eat generation starts in the beginning of the process.
20. - is the stage in which the thermal zone around the tool becomes steady.
a)Transient stage b)Dwell c)Pseudo Steady State d)none of these
Ans:-c
21.In electron beam welding the tungsten filament heated upto high temperature at
degree Celsius.
Ans:-2500
22..In electron beam welding the filament heated upto high temperature at 2500 degree
Celsius.
Ans:-Tungsten
Ans:-c
Ans:-a
Ans:-b
Ans:-c
Answer: c
Explanation: In the LBM process, the laser beam is directed by flat optical elements, such as
mirrors and then focused to a small spot (for high power density) at the workpiece using either
reflective focusing elements or lenses.
31. In case of laser welding, heat input is to fuse the weld metal.
a) equal to the required amount b) close to the minimum required
c) greater by 200 J than required d) approximately higher by atleast 320 J
Answer: b
Explanation: Following are the few advantages of Laser Beam Welding:
• Heat input is close to the minimum required to fuse the weld metal
• Reduced heat affected zones
• Workpiece distortions are minimized due to smaller heat affected zones.
32..In LBW the atoms of absorb the energy and electron of those atoms get
excited.
Ans:-a
33. Tool in USM is generally made from which of the following materials?
a) Glass b) Ceramic c) Carbides d) Steel
Ans:-d
Explanation: The tool material should be such that indentation by the abrasive grits does not
lead to brittle failure. Thus the tools are made of tough, strong and ductile materials like steel,
stainless steel and other ductile metallic alloys.
Answer: b
Explanation: During ultrasonic machining, as the tool vibrates over the workpiece, the abrasive
particles act as the indenters and indent both the work material and the tool.
Answer: b
Explanation: During USM, as the tool vibrates, it leads to the indentation of the abrasive grits.
During indentation, due to hertzian contact stresses, cracks would develop just below the
contact site then as indentation progresses the cracks would propagate due to increase in stress
and ultimately lead to brittle fracture of the work material under each individual interaction site
between the abrasive grits and the workpiece.
36. Increasing volume concentration of abrasive in slurry would affect MRR in which of the
following manner?
a) increase MRR
b) decrease MRR
c) would not change MRR
d) initially decrease and then increase MRR
Answer: a
Explanation: The concentration of abrasive grits in the slurry is related as follow
n = (6AC)/ πdg2,
where n= number of grits
A= total surface area of the tool facing the workpiece
C= concentration of abrasive grits in the slurry
dg= diameter of a grit
Thus above relation shows that any increase in ‘C’ will increase ‘n’ and hence material removal
rate (MRR).
37. Which of the following material is not machined by USM?
a) Brittle metals b) Glass c) Ceramics d) Ductile materials
Answer: d
Explanation: USM is used for machining;
• hard metallic alloys • brittle metallic alloys • semiconductors • glass • ceramics
• carbides.
Ans:-b
Explanation: The development of USM was started in 1927. It was accidentally discovered
during investigating the ultrasonic grinding of abrasive powders.
39. Which of the following is not a part of the ultrasonic machine used in USM?
a) Generator b) Acoustic head c) Slurry pump d) Lead-screw
Answer: d
Explanation: The basic ultrasonic equipment consists of, a generator for high frequency
oscillations; an acoustic head, consisting of a transducer and a horn also known as shank or
trunk; also, tool and abrasive slurry elements like pump and tank for slurry.
Answer: c
Explanation: The tool is attached to the trunk or the horn by silver brazing process. At times it is
fasten or the screwed to the trunk also. The commonly used tool materials are brass, high speed
steel, mild steel, silver, stainless steel, tungsten carbide and monel metal.
Ans:-a)
43. In plasma spray coating the temperature of plasma is as much as degree Celsius
Ans:-16000
44. The process utilizes a combination of oxygen with various fuel gases hydrogen,
propane, propylene.
Ans:-d
Ans:-a
d)None of these
Ans:-c
47.In cryogenic welding the cryogenic phenomenon includes the material processing under
degree Celsius temperature.
Ans:- c
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Academic Year 2019-20
2. STEM process is used in aerospace industries to drill the holes with high length to diameter ratio up to
.
Ans:- d
3. Generally in STEM process acid based electrolyte such as sulphuric acid having % concentration
in water.
Ans:-c
4. In STEM process how much low voltage applied across the gap as higher voltage causes boiling of
electrolyte which eventually damages the electrode coating.
Ans:-a)
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a) ECG b)STEM c)EDMd)EJM
6)Using STEM process Small holes in diameter with high length to diameter ratio.
Ans:-a
7. Which material is used as a tool for STEM to resist acid attack by electrolyte.
Ans:-d
Ans:-d
9. During the STEM process the tool feed rate is around mm/min.
Ans:-a
10. Amongs all these which of the material is not used commonly as bonding material in Electrochemical
Grinding.
Ans:-b
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11.A constant inter-electrode gap is maintained considering the grain size of the abrasive
particle.
Ans:-a)
Ans:-a
Ans:-b
15. The surface speed of the wheel during the operation is up to m/s.
Ans:-c
16. The depth of cut of the ECG process should be less than mm.
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Ans:-d.
17. The electrolyte used in the ECG are sodium chloride(NaCL) and Sodium Nitrate(NaNO 3).
a)True b)False
18. .The surface speed of the grinding wheel during the operation is up to m/s.
Ans:-c
19. has significant effect on surface finish and material removal rate.
Ans:-a
Ans:-c
21. The ELPD dresses of grinding wheels using the princople of electrolysis.
Ans:-c
Ans:-a
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23. The wheel loading and glazing can be eliminated by introducing electrolize cell.
Ans:-b
Ans:-b
Answer: c
Explanation: ECG removes metal by combination of electro-chemical and grinding actions. The grinding
action removes the buildup of oxide film on the surface of the workpiece.
Answer: c
Explanation: Desirable electrolyte should provide: high conductivity, high stock removal efficiency,
passivation to limit stray currents, good surface finishes and corrosion inhibition.
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28. Which of the following is true about ECG?
a) Lower MRRs when grinding hard, heat sensitive materials
b) Machining of soft metals like aluminium can be easily done
c) Difficult to machine materials with high hardness like tungsten carbide
d) Burr-free sharpening of needles
Answer: d
Explanation: Applications of ECG are as follows;
(1) Single largest use for ECG is in the manufacturing and remanufacturing of turbine blades and vanes
for aircraft turbine engines
(2) Grinding of tungsten carbide tool inserts
(3) Re-profiling worn locomotive traction motor gears
(4) Burr-free sharpening of hypodermic needles
(5) Grinding of surgical needles, other thin wall tubes, and fragile parts
(6) Machining of fragile or very hard and tough material – honey comb, thin walled tubes and skins
(7) High MRR’s when grinding hard, tough, stringy, work-hardenable or heat sensitive materials.
nswer: b
Explanation: In ECM, material removal takes place due to an atomic dissolution of work material.
Electrochemical dissolution is governed by Faraday’s laws. Also, for ECM, MRR= IA/(Fρv), where I=
current, ρ= density of the material, A= atomic weight, v= valency, F= faraday’s constant.
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c) higher viscosity
d) corrosive nature
Answer: a
Explanation: Desirable properties of the electrolytes are as follows:
• High electrical conductivity – for easy ionization
• Low viscosity – for easy flow
• High specific heat – to carry more heat
• Chemical stability – to be chemically neutral or
does not disintegrate during the reaction
Ans:-a
32.In EJM a higher voltage of V is applied get longer and thinner flow of electrolyte .
Ans:-b
Answer: d
Explanation: Lasing process describes the basic operation of laser, i.e. generation of a coherent (both
temporal and spatial) beam of light by “light amplification” using “stimulated emission”.
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b) Alloying
c) Nitriding
d) Cutting
Answer: c
Explanation: Laser Beam Machining or more broadly laser material processing deals with machining and
material processing like heat treatment, alloying, cladding, sheet metal bending, etc.
Answer: a
Explanation: As laser interacts with the material, the energy of the photon is absorbed by the work
material leading to rapid substantial rise in local temperature. This in turn results in melting and
vaporisation of the work material and finally material removal.
Answer: b
Explanation: Population inversion can be carried out by exciting the gas atoms or molecules by pumping
it with flash lamps. Then stimulated emission would initiate lasing action. Stimulated emission of
photons could be in all directions.
37. The depth of the surface modification depends on the heat input and the depth in the range of
is hardened using laser based heat treatment.
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a)0.025-0.01 b)0.25-2.5mm c)1.5-4.0 mm d)None of these
Ans:-b
Ans:-d
39. In magnetic abrasive finishing, particles mixed with the fine abrasive particles.
Ans:-a
42. In which process mechanical energy of water use and abrasive phase is use to achieve material
removal or machining.
Ans:-c
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43. The following figure is shows the setup of process.
Ans:-b
44. In Abrasive Water Jet Machining process, the water in converted into Kinetic energy, yielding a high
velocity jet of m/s.
Ans:-d
45. In AWJM hydraulic intensifier increases water pressure of bar to about 3000-4000 bars.
Ans:-a
Answer: c
Explanation: Wire-cut EDM process can cut plates as thick as 300mm and is used for making punches,
tools and dies from hard metals that are difficult to machine with other methods.
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47. 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.
48. 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.
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.
50. During the WEDM process, workpiece undergoes a number of thermal cycles.
a) True
b) False
Answer: a
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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.
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.
nswer: 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.
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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.
54. In wire-cut EDM process, material removal takes place by a series of discrete discharges between
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.
Answer: c
Explanation: The subsystems of Wire-EDM process are:
• Power supply
• Di-electric system
• Wire feeding system
• Positioning system.
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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.
57. 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-sink ED
machining. The basic elements in all EDM methods are dielectric fluid, a workpiece and an electrode.
58. 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.
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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.
60. 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.
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.
62. For machining of high melting point materials, wires are used.
a) gallium
b) zinc coated
c) aluminium coated
d) silver
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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.
63. 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.
Ans:-b
Ans:-c
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66. ECDM uses welding copper plates and foils.
Ans:-a
Ans:-c
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DEPARTMENT OF MECHANICAL ENGINEERING
Academic Year 2019-20
a)1µm
b)0.1 µm
c)0.01 µm
d)0.001 µm
Ans:-c
a)1µm
b)0.1 µm
c)0.01 µm
d)0.001 µm
Ans:-d
3. DTM is used to manufacture either having component feature less than _ µm or to achieve
submicron/ nano metric surface finish.
a) 1
b)10
c)100
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d)0.1
Ans:-c
4. In DTM process diamond is mostly prefer for machining of nonferrous metal such as .
a)copper
b) cobalt
c)Nickel
d)Nital
Ans:-a
5. The tool nose radius used for DTM process is varies from _ mm.
a)0.1 to 0.2
b)0.2 to 0.3
c)0.1 to 0.3
d)0.2 to 0.4
Ans:-d
6. In DTM process diamond can convert to at high temperature above 700degree celsius.
a)Silica
b)carbide
c)graphite
d)ferrite
Ans:-c
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7. Which of them are the parameters of tool geometry in DTM.
a)Cutting Edge
b)Clearance angle
c)Cylindrical tool
d)all of these
Ans:-d
a)Ultrasonic Micromachining
b)DTM
c) FIBM
Ans:-b
a)Spindle ratio
b) Feed rate
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c) depth of cut
d)Clearance feed
Ans:-d
10. Ultrasonic micromachining use to machine hard and brittle materials such as
a)sapphire
b)aluminium
c)cuprous
d)iron
Ans:-a
11. The size of the abrasive particle in USMM process is in range of µm.
a)0.5-15
b)0.1-5
c)1-5
d)0.01-0.5
Ans:-a
12. In the process the vibration is given to the tool or the workpiece.
a)USM
b)USSM
c)USW
d)none of these
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Ans:-b
a)Ultrasonic Micromachining
b)DTM
c)FIBM
Ans:-a
a)CNC controller
b)Abrasive Slurry
c)transformer
d)Acoustic head
Ans:-c
15. THe USMM employs mechanical vibration with frequency within range of kHz.
a)50-100
b)20-40
c)10-60
d)4-10
Ans:-b
16. In USMM , mechanism used to removed the material due to repetitive impact of the free
moving abrasive particles on the workpiece surface.
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a)Mechanical Abrasion
b)Cavitations effect
c)Micro chipping
d)Chemical Action
Ans:-c
17. In USMM the size of the abrasive particles is varies in the range from grit.
a)10-50
b)200-2000
c)500-1000
d)100-200
Ans:-b
18. Which of these is not the performance characteristics of the USMM process.
a)Aspect ratio
d) Tool geometry
Ans:-d
19. In Focused Ion Machining Process is a phenomenon whereby atoms are ejected from
solid target material by transfer of kinetic energy from incident ion to the target atoms.
a) Sputtering
b) collision cascade
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c) Amorphization
d)None of these
Ans:-a
20. In in FIB process several atoms will be ejected from the target surface and incident ion
implanted deep inside the target surface and damage the lattice structure by displacing adjacent atom.
a) Sputtering
b)collision cascade
c)Amorphization
d)None of these
Ans:-b
a)High
b) Low
c)Medium
d)Higher USSM
Ans:-b
22. In FIB the ion column is tilted degrees to electron column so that the real time image can be
seen easily.
a)20
b)45
c)52
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d)56
Ans:-c
a)reflecting base
b) Ion Column
c) Electron Column
d) Gas injection
Ans:-a
a)Ultrasonic Micromachining
b)DTM
c) FIBM
Ans:-c
25. What is(are) the factors below that affect the machining characteristics?
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a) Sputtering speed
b)Electron speed
c)Amorphization
d)Angle of incident
Ans:-d
26. Which process is generally use to manufacture the integrated circuit in the electronics industries.
a)Ultrasonic Micromachining
b)Lithography
c)FIBM
Ans:-b
a)Ultrasonic Micromachining
b) FIBM
c)Lithography
Ans:-c
a)Optical
b) X-Ray
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c) Electron beam
d) all of these
Ans:-d
a) Ultrasonic Micromachining
b) FIBM
c)Lithography
Ans:-c
30. In Lithography, once the substrate is prepared, is the n cooled with organic polymer known as
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a) photoresist
b) positive working
c) Negative working
d)None of these
Ans:-a
31. In lithography prebaking the wafer is the process to remove the solvent from the photoresist which is
carried out on heated around 100 degree Celsius.
a)Panel
b)Hot plate
c)base plate
d)transparent glass
Ans:-b
32. The source of radiation in X-ray which is having a shorter wavelength in range of nm
generated by the synchronous source.
a)1-5
b)0.2-1.5
c)0.4 - 4
d)1.5 - 5
Ans:-c
33. In the process chemical milling is done used to fabricate sheet metal component using
photoresist method.
| 11
a) Photo tool Production
b) X-Ray Lithography
c)Electron-beam Lithography
d)Photochemical Machining
Ans:-d
a)Prebake
c)developing
d)Matching
aAns:-a
35. From the below one of the process is not the step in Photochemical Machining.
a)Prebake
c)developing
d)Matching
Ans:-a
36. In abrasive jet machining, material is removed by shear as well as brittle deformation of the material.
a) True
b) False
| 12
Answer: a
Explanation: If the KE of the abrasive particle is high enough, then it will remove the material by shear
deformation in case of ductile workpiece material and by brittle fracture if workpiece material is brittle.
Answer: c
Explanation: In AJM, holes up to 66 μm deep can be drilled without employing any special techniques. This
process is also useful for producing microcavity.
Answer: a
Explanation: In this process, localized intense heat is produced which increases temperature of the workpiece
in a narrow zone (i.e.Beamdiameter), equal to its melting or vaporization temperature. Which leads to removal
of material at micro/nano level in the form of debris (irregular shaped particles or spherical globules).
Answer: b
Explanation: Magnetic Float Polishing is a technique based on the Magnet on hydrodynamic behaviour of the
magnetic fluid which in the presence of magnetic field can levitate a non-magnetic float and abrasive particles
suspended in it.
| 13
40. Abrasive flow machining (AFM) is used for
a) de-burring
b) etching
c) drilling
d) cutting
Answer: a
Explanation: AFM was developed by Extude Home Corporation USA in 1960 as a method to deburr, polish
and radius difficult to reach surface like intricate geometries and edges by flowing an abrasive laden
viscoelastic medium over them.
41. Thermal micromachining processes can be used to produce reduced hole diameter, lower hole pitch.
a) True
b) False Answer: a
Explanation: Reduced hole diameter, lower hole pitch and longer head can be manufactured by thermal
micromachining processes. These processes are used to manufacture computer hard disc drive heads, inkjet
printer heads, sensors, infrared images.
42. MAF was developed to produce efficiently and economically good quality finish material.
a) True
b) False
Answer: a
Explanation: MAF was developed to produce efficiently and economically good quality finish on the internal
and external surface of tubes as well as flat surface made of magnetic or non-magnetic material.
| 14
Ans:- Answer: c
Explanation: This method is used for making accurate shallow holes or grooves, and, with the use of masks,
patterns on target material.
Answer: a
45 Explanation: Advantages of AJM:
(1) low capital and operating costs,
(2) environment-friendly process,
(3) no major health hazards, and
(4) ability to machine anisotropic and suspended structures on the same substrate.
Define Amorphization.
| 15
Unit-I
Which of the following is not used in
1 1
electromagnetic forming process?
OPTION A A capacitor bank
OPTION B A forming coil
OPTIONC A foeld shaper
OPTION D Stiffening ribs
ANSWER D
75 1
Which process got a better dimensional accuracy?
Option A Hot working
Option B Cold working
Option C Warm working
Option D Both Hot working and Cold working
Answer A
89 2
Option A Roll
Option B Electro Hydraulic
Option C explosive
Option D petro-forge
Answer C
OPTION A D-E-C-B-A
OPTION B D-C-E-A-B
OPTIONC A-E-C-B-D
OPTION D A-B-C-D-E
ANSWER C
2 In the wire-cut EDM process, de-ionizing units are used for controlling the _____ 1
Option A feed rate
Option B resistivity
Option C burr formation
Option D temperature of the wire
Answer B
3
Electrically conductive materials are cut by WEDM process by _____ mechanism. 1
Option A thermal
Option B electro-thermal
Option C electro-dynamic
Option D fused metal
Answer B
7
Wire electric discharge (E machining is based on the same principle as that of _____ 1
Option A hydro-dynamic EDM
Option B die-sink EDM
Option C polar EDM
Option D non-conventional EDM
Answer B
10 What are all the types of materials, which can be machined using AWJM? 1
Option A Glass
Option B Ceramics
Option C Concrete
Option D All of the mentioned
Answer D
13
Which of the following is not a process parameter of Abrasive water jet machining 1
Option A Frequency of vibration
Option B Orifice diameter
Option C Pressure
Option D Stand-off distance
Answer A
16 In Magnetic abrasive finishing, which of the following particles do not contribute to the m 1
Option A Abrasive particles
Option B Magnetic particles
Option C Non-magnetic particles
Option D All of the mentioned
Answer C
19
A small gap between the grinding wheel and the electrode should be maintained 1
Option A to avoid electrical contact
Option B to avoid direct contact
Option C to avoid removal of oxide layer
Option D to pass an adequate flow of electrolyte
Answer D
STEM process is used in aerospace industries to drill the holes with high length to
21
diameter ratio up to_____ 1
Option A 200:1
Option B 100:1
Option C 150:1
Option D 300:1
Answer D
Generally in STEM process acid based electrolyte such as sulphuric acid having
22
______ % concentrationin water. 1
Option A 50
Option B 20
Option C 10
Option D 5
Answer C
23 In STEM process how much low voltage applied across the gap as higher voltage
causes boiling of electrolyte which eventually damages the electrode coating. 2
Option A 5-15 V DC
Option B 10-20 V DC
Option C 1-5 v DC
Option D 20-35 v DC
Answer A
24
Using STEM process Small holes in diameter with high length to diameter ratio 2
Option A 0.76-1.62 mm
Option B 1.2 - 2.4mm
Option C 0.05 - 0.225mm
Option D 0.95-3.32 mm
Answer A
25 Which material is used as a tool for STEM to resist acid attack by electrolyte. 2
Option A Tungsten
Option B Aluminium
Option C Copper
Option D Titanium
Answer D
Amongs all these which of the material is not used commonly as bonding material in
27
Electrochemical Grinding. 2
Option A Copper
Option B Cobalt
Option C Brass
Option D Nickel
Answer B
30 ______ has significant effect on surface finish and material removal rate. 2
Option A Current density
Option B Air gap
Option C Flow of electrolyte
Option D Feed
Answer A
In EJM a higher voltage of_____ V is applied get longer and thinner flow of electrolyte
35
. 2
Option A 50-100
Option B 150-750
Option C 200-400
Option D 600-1000
Answer B
In which process mechanical energy of water use and abrasive phase is use to
38
achieve material removal or machining. 2
Option A AFF
Option B ECG
Option C AWJM
Option D FMAB
Answer C
In AWJM hydraulic intensifier increases water pressure of bar to about 3000-4000
39
bars. 2
Option A 4
Option B 16
Option C 24
Option D 10
Answer A
41
Which of the following component of the wire cut EDM machine does not get heated? 2
Option A Workpiece
Option B Electrode wire
Option C Di-electric fluid
Option D Coils
Answer B
43 For machining of high melting point materials, ________ wires are used 2
Option A gallium
Option B zinc coated
Option C aluminium coated
Option D silver
Answer B
2
Micro Machining has ability to produce features with the diamentions as small as ___ 1
Option A 1nm to 999nm
Option B 1µm to 999µm
Option C 1mm to 100mm
Option D 100µm to 9999µm
Answer B
3 Lithography based micro machining technology uses _____ as materials. 1
Option A Steel
Option B Lithium
Option C Carbides
Option D Silicon
Answer D
4 Diamond Micro Machining uses diamond as a cutting tool material because _____ 1
Option A Diamond has a high coefficient of friction
Option B Diamond has low hot hardness
Option C
Diamond has a crystalline structure which allows to produce a very sharp cutting edges.
Option D None of the above
Answer C
5 Ion implantation is a technique to do what? 1
Option A Dope a semiconductor.
Option B Deposit an insulating layer on a semiconductor
Option C Deposit a metallic layer on a semiconductor.
Option D Deposit an insulating layer on an insulator.
Answer A
6 What is “lithography” used for in semiconductor manufacturing? 1
Option A To dope semiconductors.
Option B To deposit amorphous films on semiconductors
Option C To deposit polycrystalline films on semiconductors.
Option D To produce patterns in the films deposited on semiconductors
Answer D
7 What is the most common insulator used in silicon manufacturing? 1
Option A Si3N4
Option B Al2O3
Option C Si02
Option D HfO2
Answer C
8 Which of the following statements is true about the magnitude of the electric field in
the transition region of an NP junction? 1
Option A It is constant in space
Option B It increases linearly from the N side to the P‐side.
Option C It decreases linearly from the N side to the P‐side
Option D It first increases linearly, reaches a peak at the junc on, then decreases linearly.
Answer D
9 Ultrasonic Micro Machining suitable for the micro machining of ______ 1
Option A Soft and brittle material
Option B Hard and brittle material
Option C Hard and ductile material
Option D None of the above
Answer B
10 Ultrasonic Micro Machining (USM) is done under what frequency? 1
Option A 5—10 Hz
Option B 5k—10 kHz
Option C 20—40 Hz
Option D 20k—40kHz
Answer D
11
What is the purpose of the softbake after resist application into the photolithography? 1
Option A To remove residual solvent from the resist layer
Option B To correct minor uniformity problems with the resist
Option C To harden the resist for the expose process step
Option D To harden the resist for the etch process step
Answer A
After the coated wafer is placed into the photolithography expose equipment, it is _______
12
prior to being exposed. 1
Option A Baked
Option B Cooled
Option C Aligned
Option D Coated
Answer C
During the coating of photoresist, the thickness of the photoresist __________________ with
13 an
increase in spin speed. 1
Option A Increases exponentially
Option B Decrease exponentially
Option C Increase linearly
Option D Decreases linearly
Answer B
14 Which of the following material is not generally machined by USM? 1
Option A Copper
Option B Glass
Option C Silicon
Option D Germanium
Answer A
15 Which of the following BEST describes the photolithography process? 1
Option A
The process step that transfers a pattern into an underlying layer or the substrate’s bulk
Option B
The process step that defines and transfers a pattern into a resist layer on the wafer
Option C The process step that deposits a resist layer on the surface of the wafer.
Option D
The process step that aligns the various layers of a microsystem device to each other
Answer B
16 Which of the following are the components of Ion beam machining? 1
Option A Vacuum chamber
Option B Voltage source
Option C Tungsten filament cathode
Option D All of the mentioned
Answer D
17 Machining rates in IBM depend on which of the following factors? 1
Option A Work piece material
Option B Ions type
Option C Incident angle
Option D All of the mentioned
Answer D
18 What is the value of voltage required for machining in Ion beam machining? 1
Option A 1 kV
Option B 2 kV
Option C 3 kV
Option D 4 kV
Answer A
19 What is the value of beam diameter that is obtained in IBM? 1
Option A 1 cm
Option B 3 cm
Option C 5 cm
Option D 7 cm
Answer C
20 Which of the following materials can be textured using the IBM process? 1
Option A Copper
Option B Nickel
Option C Stainless steel
Option D All of the mentioned
Answer D
21 Which of the following are the applications of IBM? 2
Option A Smoothing laser mirrors
Option B Polishing surfaces
Option C Shaping surface
Option D All of the mentioned
Answer D
22 What are the accuracy levels that are obtained by using IBM? 2
Option A ± 1.0%
Option B ± 2.0%
Option C ± 3.0%
Option D ± 4.0%
Answer A
23 What are the dimensions that can machined on IBM? 2
Option A 0.1 to 1 nm
Option B 1 to 10 nm
Option C 10 to 100 nm
Option D 100 to 1000 nm
Answer C
In this method, which of the following techniques are used to apply the maskant on the
24
machining surface? 2
Option A Photographic techniques
Option B Cut and peel masking
Option C Silkscreen resist technique
Option D None of the mentioned
Answer A
25 What are the values of current densities required in IBM? 2
Option A 0.25 mA/cm2
Option B 0.35 mA/cm2
Option C 0.55 mA/cm2
Option D 0.85 mA/cm2
Answer D
26 In ultrasonic machining, the abrasive particles act as the __________ 2
Option A chip carriers
Option B intenders
Option C finishing particles
Option D thickening agent for the slurry
Answer B
27 Which of the following is the first step in Photo chemical milling process? 2
Option A Generation of photographic film
Option B Etching the part
Option C Removal of etchant
Option D Photo resist stripping
Answer A
28
Which of the following processes does not come under Chemical machining processes? 2
Option A Chemical milling
Option B Photo forming
Option C Photo chemical filling
Option D Photo chemical blanking
Answer B
29 Which of the following is the first step in Photo chemical milling process? 2
Option A Generation of photographic film
Option B Etching the part
Option C Removal of etchant
Option D Photo resist stripping
Answer A
In case of photochemical milling that use using lettering and graphics for surface etching,
30
what will be the depth of surface etched? 2
Option A Very deep
Option B Up to certain depth
Option C Half‐way
Option D None of the mentioned
Answer B
31 In some cases, Photochemical milling can also be called as? 2
Option A Photo chemical blasting
Option B Photo chemical blanking
Option C Photo chemical drilling
Option D Photo chemical erosion
Answer B
32 In USM, material removal may occur due to ______ 2
Option A fatigue failure
Option B fouling failure
Option C free flowing impact of the abrasive
Option D creep
Answer C
33 Which of the following materials is not used as abrasive in ultrasonic machining? 2
Option A SiC
Option B Boronsilicarbide
Option C Diamond
Option D TiC
Answer D
34 Which of the following is not the component of USM machine? 2
Option A Slurry delivery
Option B Transducer
Option C Concentrator
Option D Lead screw
Answer D
35 Which of the following is not machined by USM? 2
Option A Brittle metals
Option B Glass
Option C Ceramics
Option D Ductile materials
Answer D
36 USM machine uses _____ axis table. 2
Option A single
Option B 2
Option C 3
Option D 5
Answer B
37 USM is a material removal process used to_____ material. 2
Option A corrode
Option B erode
Option C melt
Option D form
Answer B
38 Which of the following is true about USM 2
Option A There is direct contact between the tool and the workpiece
Option B There is no direct contact between the tool and the workpiece
Option C This process is not suitable for machining of brittle materials
Option D This process consumes very less power
Answer B
39 During USM __________ is converted into mechanical vibrations. 2
Option A pressure energy of the slurry
Option B electrical energy
Option C chemical energy of the chemical used for the slurry
Option D mechanical energy of the tool
Answer B
40 Which of the following pumps is used in USM? 2
Option A Re‐circulating pump
Option B Centrifugal pump
Option C Vane pump
Option D Reciprocating pump
Answer A
Unit-V
Question No. Question Marks
Additive manufacturing of a design, often iterative, for form, fit, or functional
1 1
testing.This statement related to which?
Option A Bio-printing
Option B Forming Advantages
Option C Material Extrusion
Option D rapid prototyping
Answer D
What's the term used to describe 3-D printing when it's used to create models for
13 1
testing a product's design?
Option A Rapid Prototyping (RP)
Option B Computer Aided Design (CAD)
Option C Fused Deposition Modelling (FDM)
Option D None of These Above
Answer A
14 What filament type does the Makerbot 5th Gen, MakerBot Mini & Lulzbot use? 1
Option A PLA
Option B ABS
Option C FX
Option D STL
Answer A
29 Most of the laser based PBF systems have low build rates of _____? 1
Option A 5-30 cm3
Option B 5-25cm3
Option C 5-20 cm3
Option D 5-15 cm3
Answer C
The LOM process uses a _________ method during the printing process to allow for
31 1
easy removal post build
Option A Slide hatching
Option B Over hatching
Option C Cross hatching
Option D None of these
Answer C
What is the paper sheet thickness of Gluing or adhesive bonding method by using Laminated
32 1
Object Manufacturing ?
Option A 70 to 200 µm
Option B 71 to 200 µm
Option C 72 to 200 µm
Option D 73 to 200 µm
Answer A
In Solid state sintering , Long sintering time and elevated temperature will result in to
35 1
_______porosity?
Option A Equal
Option B High
Option C Low
Option D None of these
Answer C
The photopolymers is in the form of a liquid resin filled inside a vat,therefore this
39 1
process is called a Vat Photopolymerization?
Option A TRUE
Option B FALSE
Answer A
Unit-VI
Q No. Question Marks
1 The different types of energies associated with a molecule are 1
Option A Electronic energy
Option B Vibrational energ
Option C Rotational energy
O ti D
Option All off the
th mentioned
ti d
Answer D
The results obtained by spectroscopic methods are less reliable, less reproducible and
2
incorrect than classical methods 1
Option A TRUE
Option B FALSE
Answer B
3 During the motion, if the centre of gravity of molecule changes, the molecule possess 1
Option A Electronic energy
Option B Rotational energy
Option C Translational energy
Option D Vibrational energy
Answer C
15 Which among the following helps us in getting a three-dimensional picture of the specim 1
Option A Transmission Electron Microscope
Option B Scanning Electron Microscope
Option C Compound Microscope
Option D Simple Microscope
Answer B
Which of the following component of the light microscope illuminates the specimen by
20
gathering diffuse rays from the light microscope? 1
Option A light source
Option B eyepiece
Option C condenser lens
Option D screws
Answer C
25 Which of the following component of TEM focuses the beam of electrons on the sample 1
Option A ocular lens
Option B condenser lens
Option C stage
Option D column
Answer B
26 The resolution attainable with standard TEM is less than the theoretical value. 1
Option A True
Option B False
Answer A
In X-ray spectrometers, the specimen or the sample is placed after which of the
30
following components? 1
Option A X-ray tube
Option B Monochromator
Option C Collimator
Option D Detector
Answer A
31 Using which of the following components is the generated x-rays focussed upon the spe 1
Option A X-ray tube
Option B Monochromator
Option C Collimator
Option D Detector
Answer C
With the help of which of the following equations is the distance calculated from a
35
known wavelength of the source and measured angle? 1
Option A Coolidge equation
Option B Bragg’s equation
Option C Debye equation
Option D Scherrer equation
Answer B
Which of the following is the most common instrument for photographic recording of
36
diffraction patterns? 1
Option A Debye-Scherrer powder camera
Option B Gamma camera
Option C Geiger tube
Option D Scintillation counter
Answer A
1
37 Diffractometers are similar to which of the following?
Option A Optical grating spectrometer
Option B Prism spectrometer
Option C Photo multiplier
Option D Photovoltaic cell
Answer A
out of following which spectroscopic technique is only giving a complete analysis and
39
interpretation the entire spectrum 1
Option A x-ray photo-electron spectroscopy
Option B energy dispersive x-ray spectroscopy
Option C nuclear magnetic resonance spectroscopy
Option D electron back scatter diffraction
Answer C
41 Nuclear Magnetic Resonance (NMR) can be performed for an atom whose spin is _____ 1
Option A Zero
Option B Non-zero
Option C finite
Option D infinity
Answer B