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Electrochemical Machining MCQ Questions & Answers

Electrochemical Machining MCQs : This section focuses on the "Electrochemical Machining". These Multiple Choice Questions (MCQs) should be practiced to improve the Electrochemical Machining skills required for various interviews (campus interview, walk-in interview, company interview), placement, entrance exam and other competitive examinations.




Question 1

Electrode gap in electro chemical machining is generally ranged from

A. 0.5 mm to 0.9 mm
B. 1.1 mm to 1.2 mm
C. 0.1 mm to 0.2 mm
D. 3.1 mm to 4.2 mm

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Question 2

Electrolytes used in ECM must posses

A. Low electrical conductivity
B. Low chemical stability
C. High electrical conductivity
D. None of the mentioned

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Question 3

In ECM, heavy electrical sparks are created.

A. TRUE
B. FALSE

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Question 4

In ECM, tool does not touch the work piece.

A. TRUE
B. FALSE

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Question 5

Which of the following is conventional machining process?

A. Electro chemical machining
B. Milling
C. Electron discharge machining
D. None of the mentioned

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Question 6

Which of the following is correct about ECM?

A. Erosion of metal takes place as a reverse process of electroplating
B. Thermal stresses are induced
C. Mechanical stresses are induced
D. None of the mentioned

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Question 7

Which of the following is not a function of electrolyte in ECM?

A. It completes the circuit
B. It helps in electrochemical reaction
C. It carries away heat and waste product
D. It provide non reactive environment

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Question 8

Which of the following is un-conventional machining process?

A. Grinding
B. Milling
C. Turning
D. Electro chemical machining

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Question 9

Which of the following material can be machined using electro chemical machining?

A. Iron
B. Rubber
C. Plastic
D. Wood

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Question 10

_____ strength of stainless steel decreases when machined by ECM.

A. Yield
B. Tensile
C. Fatigue
D. Notched-tensile

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Question 11

Commercial ECM is carried out at a combination of ___________

A. low voltage high current
B. low current low voltage
C. high current high voltage
D. high voltage only

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Question 12

Conductivity of the electrolyte is unaffected by the loss of hydrogen during electrolysis.

A. TRUE
B. FALSE

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Question 13

Conductivity of the solution can be increased by_____

A. increasing the gap between the tool and the workpiece
B. increasing the temperature of the solution
C. increasing the concentration of the solution
D. using conductive workpiece

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Question 14

Discrepancies are sometimes observed between theoretical and actual metal removal rates and electrode feed rates.

A. TRUE
B. FALSE

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Question 15

ECM can also be called as un-controlled anodic dissolution.

A. TRUE
B. FALSE

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Question 16

ECM process is based on which of the following laws?

A. Coulomb’s law
B. Faraday’s law
C. Law of definite proportions
D. Law of chemical combination

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Question 17

Electro-chemical machining is opposite of electrochemical coating.

A. TRUE
B. FALSE

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Question 18

Electrolyte flow plays an important role in ECM.

A. TRUE
B. FALSE

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Question 19

Electrolyte should carry away the heat generated and products of the reaction.

A. TRUE
B. FALSE

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Question 20

Electrolyte used in ECM should have _____________

A. high specific heat
B. lower resistance to film formation on the workpiece
C. higher viscosity
D. corrosive nature

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Question 21

For ECM of steel which is used as the electrolyte?

A. Kerosene
B. NaCl
C. Deionised water
D. HNO3

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Question 22

For ECM, tool dimensions are different from the actual mirror dimensions of the part to be machined.

A. TRUE
B. FALSE

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Question 23

For which of the following ECM cannot be undertaken?

A. Steel
B. Nickel based superalloy
C. Aluminium oxide
D. Titanium alloy

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Question 24

For which of the following ECM cannot be used?

A. Tapering a predrilled hole in iron block
B. To make stepped hole is a nickel alloy
C. To generate ribs on metal surface
D. To machine Al2O3

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Question 25

Foreign particle in electrolyte or insulation failure within tool can cause_____

A. random inaccuracy in work
B. ripples on work
C. cavitation
D. spark damage to work

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Question 26

In ECM of pure iron a material removal rate of 600 mm3/min is required. What will be the current requirement?

A. 157A
B. 183.6A
C. 247.8A
D. 268.8A

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Question 27

In ECM operation of pure iron an equilibrium gap (h) of 2 mm is to be kept. What will be the supply voltage (v), if the total overvoltage is 2.5 Volts. The resistivity(r) of the electrolyte is 50 Ω-mm and the set feed rate (f) is 0.25 mm/min.

A. 5v
B. 7.8v
C. 11.3v
D. 13.2v

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Question 28

In ECM, accuracy of the product is independent of the accuracy of the cathode tool.

A. TRUE
B. FALSE

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Question 29

In ECM, electrode or tooling cost is fixed because_____

A. there is little wear of the tool
B. tool can be used only once
C. tool can be regenerated
D. one tool can be used for any product

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Question 30

In ECM, material removal rate does not depend on chemical properties of the anode material.

A. TRUE
B. FALSE

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Question 31

In ECM, one needs to understand fluid flow while designing the tool for machining complex shapes.

A. TRUE
B. FALSE

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Question 32

In ECM, shape of the cathode does not affect the shape of the machined product.

A. TRUE
B. FALSE

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Question 33

In ECM, workpiece acts as a cathode.

A. TRUE
B. FALSE

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Question 34

Increase in pressure of the electrolyte above atmospheric pressure is beneficial.

A. TRUE
B. FALSE

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Question 35

MRR is ECM depends on _____________

A. hardness of work material
B. atomic weight of work material
C. thermal conductivity of work material
D. ductility of work material

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Question 36

Precipitate formation reduces the conductivity of the electrolyte solution.

A. TRUE
B. FALSE

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Question 37

Solubility of the reaction products increases with_____

A. increase in pressure of the electrolyte
B. increase in temperature of the electrolyte
C. increase in work-tool gap
D. decrease in temperature of the electrolyte

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Question 38

Spraying or dipping method is used for applying insulation.

A. TRUE
B. FALSE

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Question 39

Striation, ripples on work surface occur because of ____

A. differential machining of material phases
B. incorrect tool alignment
C. cavitation
D. electrical field concentration of machining current

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Question 40

The insulation in ECM should have_____

A. adhesion to the tool
B. roughness
C. high water absorption tendency
D. chemically active

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Question 41

Pick the incorrect one from the following options.

A. Voltage across the cutting gap influences the current and the MRR
B. Higher voltage decreases the equilibrium machining gap
C. Increased current leads to electrolyte heating
D. ECM can be used for facing and turning complex 3D surfaces

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Question 42

The tool in ECM should have which of the following properties?

A. High machinability
B. Lower corrosion rate
C. High softness
D. High conductive resistance

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Question 43

The velocity and the electrolyte flow through the gap is also an important parameter affecting the surface finish and MRR.

A. TRUE
B. FALSE

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Question 44

There is a huge change in the mechanical properties of the material after ECM.

A. TRUE
B. FALSE

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Question 45

There is a limit to the minimum cross-section of the current carrying parts.

A. TRUE
B. FALSE

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Question 46

In order to obtain good results in ECM, _____

A. maximise polarization
B. allow rise in temperature of the electrolyte
C. removal of used electrolyte form the working gap
D. decrease the concentration of the electrolyte

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Question 47

Tool used in ECM should have higher rigidity.

A. TRUE
B. FALSE

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Question 48

Tool with an electrolyte supply slot leaves small ridge on the work.

A. TRUE
B. FALSE

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Question 49

What does faraday’s second law electrolysis state?

A. W∝Q, where W= mass of substance deposited and Q= charge passed through the electrolyte
B. w1/w2 = E1/E2, where w1 and w2 = mass of different substances deposited, and E1 and E2 = their equivalent masses
C. Induced EMF = – dΦ / dt
D. Force between two charge particles q1 and q2, F= kq1q2/r2

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Question 50

What is faraday’s first law of electrolysis?

A. W∝T, where W= mass of substance deposited and T= temperature of the electrolyte
B. W∝K, where W= mass of substance deposited and K= ionisation constant of the electrolyte
C. W∝Q, where W= mass of substance deposited and Q= charge passed through the electrolyte
D. W∝ 1/Q, where W= mass of substance deposited and Q= charge passed through the electrolyte

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Question 51

Which of the following conditions are desirable for ECM?

A. High value DC and low value electric potential
B. Low value DC and high value electric potential
C. High value DC and high value electric potential
D. Low value DC and low value electric potential

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Question 52

Which of the following does not hold true about ECM?

A. ECM cell must avoid flutter and arcing
B. Part and the cathode must have adequate current-carrying capacity
C. Tool must have shape exactly same as that of the mirror image of the part
D. It gives burr free surface

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Question 53

Which of the following does not hold true about ECM?

A. Lower current density leads to poor surface finish
B. Small gap between tool and the workpiece can cause short circuit
C. Gap between the tool and the workpiece doesn’t affect the process parameters
D. MRR is dependent on feed rate and electrolyte composition

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Question 54

Which of the following holds true about electro-chemical machining?

A. Material is removed from the cathode and deposited on the anode
B. Material is removed from the anode and carried away by the electrolyte
C. Major drawback is that the finished product has residual stresses
D. It can also be used for all non-metals

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Question 55

Which of the following is a sludging type electrolyte?

A. NaOH solution
B. KOH solution
C. NaCl solution
D. CuSO4 solution

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Question 56

Which of the following is not a desirable electrolyte property?

A. Low viscosity
B. High specific heat
C. Lower resistance to film formation on the workpiece
D. Non-corrosiveness

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Question 57

Which of the following is suitable if work surface finish is important?

A. High machining voltage
B. High concentration
C. Larger gap
D. High current

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Question 58

Which of the following is true about ECM process?

A. Unable to machine high strength materials
B. Excessive tool wear
C. It gives burr free surface
D. Surface hardness of the workpiece gets reduced

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Question 59

Which of the following largely affects the MRR?

A. ECM cell size
B. Tool shape
C. Feed rate
D. Complexity of the product

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Question 60

Which of the following manufacturing process is favourable for making tool for ECM?

A. Casting
B. Cold forging
C. Laser cutting
D. Shaping

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Question 61

Which of the following materials can be used for making work holding devices?

A. Steel
B. Rubber
C. Graphite fibres
D. Wood

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