ME-702-A Advance Machining Processes - Jun 2025 Question Paper

Under each question, How to answer lists the points an answer should cover, outlined by CampusPrep from the syllabus. Check the details against your textbook.

1. 6 Marks
   aExplain the need of unconventional machining processes compared to the conventional ones.
   How to answer

   • Define conventional vs unconventional machining
   • Limitations of conventional: hard materials, complex shapes, tool wear
   • Need: hardness, brittleness, precision, miniaturization, surface integrity
   • Comparison of material removal mechanisms
2. 4 Marks
   bWhat are the process parameters on which AJM process depends?
   How to answer

   • Define AJM process
   • Abrasive parameters: type, size, flow rate
   • Gas parameters: pressure, velocity, composition
   • Nozzle and process geometry: SOD, angle, mixing ratio
3. 4 Marks
   cBriefly explain the working of an USM machine showing important elements.
   How to answer

   • Principle: ultrasonic vibration + abrasive slurry
   • Important elements: transducer, concentrator, tool, slurry system
   • Working cycle and material removal by hammering
   • Applications and limitations
4. 7 Marks
   aDescribe the chemistry involved in ECM. What is the effect of temperature and pressure of electrolyte in ECM process?
   How to answer

   • Anodic dissolution and Faraday laws in ECM
   • Electrolyte reactions, e.g. NaCl with iron workpiece
   • Effect of temperature on conductivity and MRR
   • Effect of pressure/flow on flushing, cavitation and accuracy
5. 7 Marks
   bExplain the working principle of EDM with a neat sketch along with its specific applications.
   How to answer

   • Principle: spark erosion in dielectric
   • Components: tool, workpiece, dielectric, pulse generator
   • Neat sketch of EDM setup with gap and servo
   • Specific applications: dies, micro-holes, hard alloys
6. 7 Marks
   aBriefly explain the working principle and components of electron beam machining processes.
   How to answer

   • Principle: high-velocity electron beam heating and vaporization
   • Components: electron gun, lenses, vacuum chamber, deflection system
   • Working sequence and beam control
   • Capabilities for micro-machining
7. 7 Marks
   bWhat do you understand by the term laser and how it is used to machine the materials?
   How to answer

   • LASER acronym and stimulated emission
   • Population inversion, pumping and resonator
   • Focusing to high power density for melting/vaporization
   • Laser machining setup and material interaction
8. 7 Marks
   aDifferentiate between the ultrasonic machining processes and abrasive jet machining processes.
   How to answer

   • USM: ultrasonic + slurry hammering; AJM: gas-borne abrasive jet
   • Comparison of tool, medium, contact vs non-contact
   • Comparison of materials, accuracy, MRR
   • Advantages/limitations of each
9. 7 Marks
   bDescribe Electro Chemical Deburring process (ECD) and what are its advantages.
   How to answer

   • Principle of ECD/EC deburring by selective anodic dissolution
   • Tooling and electrolyte flow at burr locations
   • Process steps and control parameters
   • Advantages: no mechanical stress, complex edges, speed
10. 7 Marks
    aBriefly explain the plasma arc machining process with neat diagram.
    How to answer

    • Principle: constricted plasma arc melting
    • System: torch, power supply, gas supply
    • Neat diagram of PAM torch and workpiece
    • Process parameters and applications
11. 7 Marks
    bList in detail economic considerations, applications and limitations of AWJM.
    How to answer

    • Economics: capital, abrasives, nozzle wear, MRR
    • Applications: composites, metals, cutting, cleaning
    • Limitations: taper, embedment, noise, thickness
    • Summary comparison with other jet processes
12. 7 Marks
    aExplain the advantages and limitations of electron discharge machining.
    How to answer

    • Advantages: hard materials, complex shapes, no contact forces
    • Precision and surface finish aspects
    • Limitations: low MRR, tool wear, power, cost
    • Restricted to conductive materials
13. 7 Marks
    bDescribe the function of the dielectric fluid in EDM processes.
    How to answer

    • Insulation and controlled spark gap
    • Cooling and flushing of debris
    • Ionization/deionization for stable discharge
    • Surface finish and safety aspects
14. 14 Marks
    What are the different types of Micro System Devices? Explain LIGA process.
    How to answer

    • Types of MEMS/Micro system devices: sensors, actuators, microfluidics
    • LIGA acronym: Lithography, Electroforming, Moulding
    • Steps: X-ray lithography, electroplating, replication
    • Applications and high aspect ratio capability
15. 14 Marks
    What do you understand by rapid prototype? Explain one of the rapid prototype fabrication process, mention its advantages and limitations.
    How to answer

    • Definition of rapid prototyping and STL workflow
    • One process e.g. SLA/FDM/SLS: steps and setup
    • Advantages: speed, complexity, low tooling
    • Limitations: material, accuracy, cost, size