This document contains questions from past exams on the topic of unconventional machining processes. It is divided into 5 units which cover various unconventional processes like ultrasonic machining, abrasive jet machining, electrical discharge machining, electrochemical machining, plasma arc machining and laser beam machining. The questions range from short definitions and explanations to longer discussions of specific processes and comparisons of different unconventional processes. The document serves as a study guide for students by providing examples of question types that may appear on exams for this subject.

1. CHENNAI INSTITUTE OF TECHNOLOGY 2017
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ME6004 UNCONVENTIONAL MACHINING PROCESSES
ME6004 UNCONVENTIONAL MACHINING PROCESSES
UNIT-1
1. What are the industrial needs for UCM? (Nov/Dec 2012)
2. What are the advantages and limitations of unconventional machining processes? (Nov/Dec 2012)
3. What are the advantages of unconventional machining processes? (May/June 2013)
4. List the unconventional machining processes based on thermal energy. (May/June 2013)
5. Write the importance of surface finishing in machining operations. (May/June 2014)
6. What is the need of unconventional machining? (Nov/Dec 2014)
7. List out the limitations of traditional machining processes. (Nov/Dec 2014)
8. Compare conventional and unconventional machining processes? (Apr/May 2015,N/D 16)
9. State the need for unconventional machining? (A/M 15)(M/J 14,16)
UNIT-2
1. What is the function of a transducer? (Nov/Dec 2012)
2. State any four important variables of AJM process. (Nov/Dec 2012)
3. Write the operating principle of Water Jet machining process. (May/June 2013)
4. What are the parameters influencing the MRR in ultrasonic machining process? (May/June 2013)
5. What are the advantages of Ultrasonic machining? (May/June 2014)
6. Write the formula for material removal rate for ductile material and brittle material in abrasive jet machining.
(May/June 2014)
7. Why is abrasive jet machining not recommended machine ductile materials? (Nov/Dec 2014)
8. What are the characteristics of a good suspension media of the USM process? (Nov/Dec 2014)
9. What is the principles of USM? (Apr/May 2015)
10. List the application of WJM? (A /M 15,N/D 16)
11. list the different types of abrasives used in AJM (N/D 16)
UNIT-3
1. What are the different dielectric media used in EDM process? (Nov/Dec 2012)
2. State any four functions of dielectric fluid. (Nov/Dec 2012)
3. Name any four electrode materials used in EDM process. (May/June 2013)
4. List out the applications of wire cut EDM. (May/June 2013)
5. Name some of the tool materials used in EDM. (May/June 2014)
6. What are functions of dielectric fluid used in EDM? (May/June 2014)
7. What is the function of servo mechanism in EDM process? (Nov/Dec 2014)
8. List out the importance of EDM process. (Nov/Dec 2014)
9. Sketch the relaxation circuit of EDM? (Apr/May 2015)
10. State the principle and limitations of EDM? (Apr/May 2015)
11. What are the roles of dielectric medium in EDM (N/D 16)

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ME6004 UNCONVENTIONAL MACHINING PROCESSES
UNIT-4
1. What is self-adjusting feature in ECM? (Nov/Dec 2012)
2. State any four factors that affect the selection of an etchant for a given component in ECM.(Nov/Dec 2016)
3. What are the maskants in chemical machining process? (May/June 2013)
4. Write the formula for finding the MRR in ECM process. (May/June 2013)
5. What are the main functions of Electrolysis in the electro chemical machining? (May/June 2014)
6. What are the parameters that affect the material removal rate in electro chemical grinding? (M/J 14)
7. Elaborate the functions of electrolyte in ECM. (Nov/Dec 2014)
8. Give the application of electro chemical grinding (Nov/Dec 2014)
9. What is mean by maskant? (Apr/May 2015)
10. Mention the application of ECH? (Apr/May 2015)
11. What is the advantages of ECG over conventional grinding (N/D 16)
UNIT-5
1. LBM and EBM both are thermal processes. However it is found that the first one results in more thermal
damage to the machined component than the second one. Is it true? Justify your answer?(Nov/Dec 2012)
2. State any four process parameters in PAM. (Nov/Dec 2012)
3. What is the principle of plasma arc machining process? (May/June 2013)
4. What are the techniques used for controlling beam in EBM process? (May/June 2013)
5. Write the advantages of plasma arc machining. (May/June 2014)
6. Can you machine electrically non-conductive materials by PAM? Just your answer.(Nov/Dec 2014)
7. Contrast LBM and EBM. (N/D14) (M/J 14)
8. Name the beam control techniques of EBM? (Apr/May 2015)
9. What is mean by laser beam drilling? (Apr/May 2015)
10. What do you mean by plasma (N/D 16)
11. What is the advantage of EBM over LBM (N/D 16)
PART B
UNIT-1
1. Name the important factors that should be considered during the Selection of unconventional machining process
for a given job. (N/D 12,16)(A/M 17)
2. With the neat sketch, explain the need of unconventional machining process. (Nov/Dec 2013)
3. Classify the unconventional machining process. (Nov/Dec 2013)
4. Compare the process capabilities and limitations of mechanical energy based, thermal energy based and
electrical energy based unconventional machining processes. (N/D 13)
5. What are the basic factors upon which the UCMP are classified? Explain. (M/J 14)
6. What are the basic limitations of conventional manufacturing process? Justify the need of UCMP in today’s
industries. (M/J 14)
7. Difference between conventional and unconventional machining process. Discuss the reasons for the
Development of unconventional machining process. (N/D 14,16)
8. Give the complete classification of unconventional machining processes with the distinctive features of each of
them. (N/D 14,16)
9. Narrate the various aspects involved in the selection of an UCMP for a specific application(A/M 15)
10. Enumerate the classification of unconventional machining processes? (A/M 15)

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ME6004 UNCONVENTIONAL MACHINING PROCESSES
11. Elaborate the classification of modern machining process on the basis of energy employed. Discuss the
mechanism of MRR and energy transfer in each category. (M/J 17)
UNIT-2
1. Enumerate with neat sketches various types of tool feed system in Ultrasonic machining process.
(N/D 12)
2. Explain the parameters that affect Abrasive Water Jet (AWJ) machining. (Nov/Dec 2012)
3. With the neat sketch, explain the abrasive jet machining process. (Nov/Dec 2013)
4. Discuss about the various parameters involved in AJM process. (Nov/Dec 2013)
5. Explain with a neat sketch, the working principle of ultrasonic machining process.(Nov/Dec 2013)
6. Discuss about the various applications of USM process.
7. Write short notes on the following related to Ultrasonic Machining (USM):
(i) Transducers used in USM machine. (ii) Functions of slurry and oscillation USM.
(iii) Types of abrasive used in USM. (iv) Grain size Vs. Machining grate
(v) MRR in USM (M/J 14,17,N/D 16)
8. Explain the variables that are affecting the material removal rate and accuracy of the Abrasive jet machining
process. (May/June 2014)
9. Discuss in detail the principle and influence of process variables upon the material removal in ultrasonic
machining. (Nov/Dec 2014)
10. Discuss the effects of various process parameters of AJM on accuracy and MRR. (Nov/Dec 2014)
11. Write a brief note on the special feature of the equipment used in water jet machining.(Nov/Dec 2014)
12. Drive the equation for volumetric material removal rate involved in grain throwing model of USM?
13. Compare the types of nozzle designs employed in AWJM with neat sketches? (APR/MAY2015)
14. Describe the process of abrasive jet machining along with the effect of all the process parameters(A/M 15)
15. Describe The Apparatus Process Parameters Process Capabilities Applications Of AJM (N/D 16)
16. What are the factors that affect the performance of WJM process discuss their effect of MRR.(A/M 17)
17. With a schematic diagram explain the working of AJM (A/M 17)
UNIT-3
1. Explain the various operating principles involved in electrical discharge machining process.(Nov/Dec 2013)
2. Discuss any four power circuits used for EDM process. (Nov/Dec 2013)
3. What is flushing in EDM process? Explain about various flushing techniques. (Nov/Dec 2013)
4. Explain with a neat sketch, the wire cut EDM process. (Nov/Dec 2013)
5. Explain the following in electro discharge machining(EDM) with neat sketch
i) Electrode feed control system.
ii) Factors to be considered for EDM machine tool selection. (May/June 2014)
6. Explain the following on wire EDM technology:
i) Dielectric system ii)Positioning system
iii) Deionized iv) Wire drive system (May/June 2014)
7. Explain the working principle, elements and characteristics of wire EDM. (Nov/Dec 2014)
8. Explain how the stratified wire works. Also discuss about the recent developments in wire EDM.(Nov/Dec
2014)
9. Explain the different types of control circuits used in EDM process. (Nov/Dec 2014)
10. Describe the wire cut EDM equipment, its working, applications and advantages. (APR/MAY-2015)
11. Write short notes on the following in the context of EDM:
(i) Types of flushing ii) Types of spark generator (iii) Types of electrode holders
(iv) Properties of dielectric. (v) MRR (A/M 15,17)(N/D 12)

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ME6004 UNCONVENTIONAL MACHINING PROCESSES
12. Discuss the effect of pulse duration on material removal rate surface finish and relative electrode wear in EDM.
(Nov/Dec2012)
13. Describe the construction and working principle of EDM process. Write its advantages, disadvantages and
Applications. Also discuss the effect of process parameters on the metal removal in EDM (N/D 16)(A/M 17)
14. Describe the construction and working principle of WEDM process. Write its advantages, disadvantages and
applications. Also discuss the effect of process parameters on the metal removal in WEDM (N/D 16)
UNIT-4
1. Discuss the various process parameters affecting the surface finish and MRR in chemical machining process
(Nov/Dec 2013)
2. List the advantages of chemical machining process. (Nov/Dec 2013)
3. Explain with a neat sketch, the electro chemical machining process. List its advantages, limitations and
applications (Nov/Dec 2013)
4. Explain the following on Electro Chemical machining process with suitable neat sketch:
i) Cathod tool ii) Correction of tool (May/June 2014)
5. Compare the Chemical Machining (CHM) with ECM respect to their process parameters. (May/June 2014)
6. Briefly discuss Electro chemical deburring process. (Nov/Dec 2014)
7. Why maskants are required in chemical machining process? Explain. (Nov/Dec 2014)
8. Describe the electrochemical honining process with a neat sketch. (Nov/Dec 2014)
9. Explain the processes of chemical blanking and chemical milling with neat sketches.(Apr/May 2015)
10. Describe the process of ECG with neat sketches. (Apr/May 2015)
11. With the help of a diagram explain the working of ECM process also write its advantages, disadvantages and
applications. (N/D 16)
12. With a neat sketch explain the principle of electro chemical grinding state its process capabilities and
applications . (N/D 16)
13. Why CHM is found to be most potential process for gear finishing explain its principle key process parameters
and other applications (A/M 17)
14. During the machining of iron (fe) using aqueous solution of Nacl, what are the possible reactions at electrodes
explain the electro chemical deburring process (A/M 17)
15. Discus about the types of maskants used in ECM and explain the basis why surface finish of a chemically
machined surface of an alloy is poor (A/M 17)
UNIT-5
1. Explain with a neat sketch, the working principle of LBM process, list its applications. (N/D13)
2. What is plasmatron? Explain various types of plasmatron. (N/D13)
3. Sketch the electron beam gun and explain the functions of each part. (N/D 13)
4. Explain the parameters that are affecting the performance of Plasma Arc Machining (PAM).(M/J 14)
5. Explain the production of laser beam and working principle of LBM process. (N/D14)(A/M 17,14)
6. Explain the principle, construction and working of EBM. Also how can a complex shape be cut using EBM
process? (N/D 14)
7. Explain the principle of PAM with sketch. (A/M 15)
8. Explain the principle of LBM with neat sketch (A/M 15)
9. Explain different types of PAM process with a neat sketch also state its advantages disadvantages and
applications. (N/D 16)
10. Explain the principles machining system process capabilities applications and advantages of EBM with a neat
sketch (N/D 16)

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ME6004 UNCONVENTIONAL MACHINING PROCESSES
11. Compare the operation of transferred and non transferred arc mode in plasma machining, write a brief note on
under water plasma cutting (A/M 17)