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ME 2026 UNCONVENTIONAL MACHINING PROCESSES

VI SEM B.E. Mechanical Engineering


UNIT-1Introduction
Part A
1. What are the characteristics of Unconventional Machining process?
2. List the unconventional machining process which uses mechanical energy.
3. What is the necessity for unconventional machining process?
4. How non-traditional machining processes are classified?
5. What are the importances of unconventional machining?
6. List the classification of unconventional machining.
7. Distinguish traditional and nontraditional machining process?8 What types of energy are
employed in nontraditional machining process?
8. What is ECM?
9.What is LBM?
10. Enlist the requirements that demand the use of advanced machining process.
11. Why conventional machining process is not so effective on soft metals like
aluminum?
12. How will you compare various nontraditional machining processes?
13. What are the different machining characteristics with respect to which the
Non-traditional machining process can be analyzed?
14. What are the industrial needs for unconventional machining process?
15. In chemical machining, what are the factors by which selection of etchantis
governed?
16. What is UCM?
17.List two demerits of UCM.
18.List out various thermal energy based process.
19. List out various mechanical energy based process.
20. List out various chemical energy based process.
Part B
1. Compare the mechanical and electrical energy processes in terms of
Physical parameters, shape capabilities, process capability, and process
economy.
2. Explain the reasons for the development of Unconventional Machining
Processes. Discuss about the criteria recommended in selection of these
processes.
3. What exactly are the items that can be considered with respect to the analysis of
economics of various non-traditional machining process? Briefly explain.
4. Make comparison among various non-traditional machining processes in terms of the
following. Presentation in the form of table is preferred.
1) pocketing operation
2) Contouring a surface
5. How will you analyze the applicability of different process with different types
ofmaterials, namely metals, alloys and non-metals? Presentation in the form of
table is preferred.
6. Make comparison between ultrasonic machining and conventional grinding.
7. What are the needs for the development of unconventional machining processes?Explain
with examples.
8. Classify unconventional machining processes based on basic mechanism involved in the
processes, source of energy required for the material removal, medium for transfer of
energies and type of energy required to shape materials.
9. Explain advantages of Various UCM process.
10.Compare and contrast between various UCM.
Unit-2Mechanical energy based processes

Part-A

1. What are the typical applications of ultrasonic machining?


2. List a few type of work materials for USM.
3. Give a few desirable properties of carrier gas in AJM.
4. List a few unique benefits of AWJM
5. What is the transfer medium in AJM and also abrasives used ?
6. What is the effect of abrasive grain size on the machining rate in USM?
7. List a few process parameters of USM.
8. Write down the principle of WJM.
9. Mention a few salient features of USM.
10. List a few applications of AJM.
11. What are the four variables that influence the metal removal rate in abrasive jet.
12. What is the need for transducer in USM?
13. Write two Application of WJM.
14. What is the working principle of USM?
15. Write any two applications of USM
16. Mention the Process parameters of WJM.
17. What is the use of catcher in the water jet machining?
18. What are the characteristics of good suspension media of the USM process?
19. What are the types of operations that can be performed in the AJM.
20. What are the major elements of the USM equipments? What is sonotrode in USM?

Part-B

1. Explain the AJM process with neat sketch, write its applications and advantages.
2. Compare between USM and conventional machining.
3. Draw a schematic layout of AJM and explain its operational characteristics. What are
the methods adopted to have an effective control over the mass flow rate of the
abrasive?
4. Explain the process of the WJM and the process parameters.
5. What are the methods of generating the ultrasonic, characteristics of the various type
of tool holder and the tool feed mechanism in USM process and the process
parameters.
6. Compare the USM, WJM, and AJM in terms of process capabilities and limitations.
7. Discuss the effect of the following parameters on the MRR and surface finish in USM
1)amplitude& frequency 2)abrasive size 3)concentration of abrasive 4)material
hardness.
8. Explain the process of AWJM and the process parameters.
9. Explain the various Process parameters of WJM& AJM
10. Explain the functions of the transducer and horns used in USM. List the tool materials.

UNIT -3 Electrical energy based processes

PART A

1.What is the purpose of dielectric in EDM?


2.Indicate the range of pulse duration and current in EDM?
3.List recent developments in EDM process?
4.What are the properties required for dielectric fluid for EDM?
5.List out the applications and limitations of EDM?
6.State the difference between wire cut EDM and EDM?
7.What is the function of servo control system in EDM?
8.List the process capabilities of EDM process?
9.What are the types of tool materials used in EDM?
10.State the functions of dielectric medium used in EDM?
11.What are the types of power generator circuits used in EDM?
12.What do you mean by recast layer with reference to the EDM?
13.What are the functions of adaptive control used for EDM?
14.What are the functions of adaptive control used for EDM?
15.Mention a few varieties of power supply circuits commonly used in electrical discharge
machining?
16.What is the principles of operation of wire-cut EDM process?
17.What are the ways of gap-flushing used in EDM?
18.What are the categories into which the variety of power supply circuits in
EDM process can be classified?
19.What is the function of servo mechanism in EDM process?
20.What are the desirable properties for dielectric fluid?
PART-B

1.Explain the process of Wire cut EDM and list its advantages and disadvantages,
applications, limitations?
2.Explain the process of EDM , its process parameters, advantages, disadvantages and
applications?
3.Explain the servo system used to control the feed rate in EDM process?
4.List out the three types of spark generators used in EDM and describe them?
5.List the recent developments in EDM process and state the limitations of EDM process?
6.Explain how MRR and quality is controlled in EDM process?
7.Explain the classification and characteristics of various spark erosion generators?
8.Explain the different types of control circuits used in EDM process?
9.Write the various types of flushing system employed in EDM process?
10.What are the basic requirements of tool materials in EDM process? Name any 4 tool
Materials?

Unit 4. Chemical and electrochemical energy based process

Part A

1. What is Principle of ECM?


2. What are the Electrolytes used in ECM?
3. What are Tool materials used in ECM?
4. List the Process parameters of ECM
5. List the Limitations of ECM
6. What is the Function of electrolyte in ECM
7. What is the Application of ECM?
8. What are the Advantages of chemical machining?
9. What is Self adjusting feature in ECM?
10. What is etch factor?
11. What are Advantages of ECM
12. List the Difference between electroplating and ECM
13. List theProcess parameters of ECG
14. Give the application of electro chemical honing
15. What is CHM?
16. What is etchant?
17. What is maskant?
18. List two ethants.
19. List two maskants.
20. List two techniques of applying maskant.

Part B

1. Explain ECM process with sketch and discuss influences of process parameters in
machining output.
2. Explain ECG process with sketch and state the process capabilities and applications.
3. What are the characteristics of electrolyte used in ECM, factors influencing the
selection of maskants in chemical machining process.
4. What does the MRR by ECG comprise? What are the functions of abrasive particles?
What type of material can be grounded in ECG?
5. Discuss about the effect of high temperature and pressure of the electrolyte on the
ECM process.
6. Describe the working principle of chemical machining. What are the factors on
which the selection of a resist for use in chemical machining.
7. Explain ECH process with sketch and discuss the applications.
8. Explain the process parameters, MRR and surface finish in CHM.
9. Explain the process parameters, MRR and surface finish in ECM.
10. Compare CHM and ECM.
Unit 5Thermal energy based processes

Part A

1. List the Limitations of EBM.


2. What do you mean by transferable arc in plasma machining? what is its use?
3. What is the Acronym of LASER
4. List the Gases used in the plasma arc machining.
5. Why deflection coil provided for EBM?
6. Write the Principle of LBM.
7. Define electron beam.
8. Contrast LBM and EBM.
9. What is Commonly used gas mixture in PAM.
10. What is the Characteristic of laser beam.
11. How EBM is different from PAM?
12. Distinguish vacuum and non vacuum EBM.
13. How EBM is different from LBM?
14. List uses of vacuum and non vacuum EBM.
15. Give the function of water muffle in PAM.
16. What is meant by the population inversion between energy levels in LBM?
17. Write the principle of PAM.
18. In EBM ,why is a high vacuum created in the apparatus.
19. List the parameters of PAM.
20. List the advantages of LBM.

PART B

1. Explain Laser beam machining and drilling with sketches.


2. Explain the Process of PAM with neat sketch.
3. Explain the Process parameters of EBM and influence on machining quality .
4. Explain EBM with neat sketch and the process parameters.
5. Explain the Process parameters of PAM and influence on machining quality .
6. Explain the Process capabilities of PAM.
7. Explain the Thermal features of LBM. Discuss the performance of various types of lasers.
8. What is non transferred and transferred mode of PAM? Explain the mechanism of material
removal in PAM.
9. Discuss the factors that influence the quality of circuit in PAM.
10. What is laser? How it is used to m/c materials?

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