ME-702-A Advance Machining Processes - Nov 2023 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. 7 Marks
   aDiscuss the mechanism of metal removal in ultrasonic machining process.
   How to answer

   • Definition of ultrasonic machining and system elements
   • Hammering and abrasive action mechanism
   • Role of cavitation and micro-chipping
   • Material removal cycle with tool vibration
2. 7 Marks
   bList any four applications of wire cut discharge machining.
   How to answer

   • Brief principle of wire-cut EDM
   • List four distinct applications
   • Type of work material / profile for each
   • Advantage enabling the application
3. 7 Marks
   aWrite the applications of ultrasonic machining process.
   How to answer

   • Principle of ultrasonic machining in brief
   • List machining applications by material type
   • Applications by component / industry
   • Limitations defining suitability
4. 7 Marks
   bExplain about Different types of errors occurred while matching the material using EDM.
   How to answer

   • EDM spark gap and accuracy concept
   • Types of errors: overcut, taper, recast layer, tool wear
   • Causes related to parameters and flushing
   • Control / minimization measures
5. 7 Marks
   aExplain the working principle of wire EDM.
   How to answer

   • Wire EDM setup and wire electrode system
   • Spark erosion working principle
   • Dielectric, flushing and CNC control
   • Continuous cutting operation
6. 7 Marks
   bExplain the effect of 'focusing' on the performance of LBM.
   How to answer

   • Laser beam machining focusing concept
   • Effect on power density and spot size
   • Impact on MRR, kerf and HAZ
   • Optimum focusing condition
7. 7 Marks
   aWhat are the three types of starting materials in rapid prototyping? Explain.
   How to answer

   • Definition of rapid prototyping starting materials
   • Liquid-based materials and example
   • Solid-based materials and example
   • Powder-based materials and example
8. 7 Marks
   bExplain how stratified wire works?
   How to answer

   • Concept of stratified / coated wire
   • Layers and material composition
   • Working during sparking
   • Advantages over plain wire
9. 7 Marks
   aState and explain the application issues in rapid prototyping.
   How to answer

   • Scope of rapid prototyping applications
   • Accuracy, material and cost issues
   • Build time and support issues
   • Post-processing and selection implications
10. 7 Marks
    bWhat are some of the basic types of micro system devices? Discuss.
    How to answer

    • Definition of micro system devices / MEMS
    • Sensor-type devices
    • Actuator-type devices
    • Microfluidic / structural devices
11. 7 Marks
    aDefine rapid prototyping and explain its significance in product development.
    How to answer

    • Definition of rapid prototyping
    • Layer-by-layer principle
    • Significance in design iteration and time
    • Significance in cost and customization
12. 7 Marks
    bExplain the principles and working of 3D printing.
    How to answer

    • Additive manufacturing principle
    • Steps: CAD, STL, slicing, building
    • Curing / bonding and finishing
    • Types and applications
13. 7 Marks
    aExplain the LIGA micro fabrication process.
    How to answer

    • LIGA acronym and principle
    • Lithography step with X-ray
    • Electroforming and molding steps
    • High aspect ratio microstructures
14. 7 Marks
    bExplain the industrial applications of micro fabrication.
    How to answer

    • Scope of micro fabrication
    • Electronics and medical applications
    • Automotive and aerospace applications
    • Benefits for miniaturization
15. 5 Marks
    aWhat is Electro chemical honing?
    How to answer

    • Definition of electrochemical honing
    • Combined ECM and honing action
    • Tool and electrolyte arrangement
    • Applications and finish obtained
16. 5 Marks
    bWhat do you understand by 'etch factor'?
    How to answer

    • Definition of etch factor in chemical machining
    • Formula relating undercut to depth
    • Significance for accuracy
    • Factors affecting etch factor
17. 4 Marks
    cExplain the mechanism of machining rate.
    How to answer

    • Concept of machining rate / MRR
    • Mechanism governing removal rate
    • Influence of process parameters
    • Relation to productivity and quality