JAYA SAKTHI ENGINEERING COLLEGE

[Approved By AICTE, New Delhi & Affiliated to ANNA

UNIVERSITY, Chennai]
Thiruninravur–602024, Thiruvallur District, Tamil Nadu.

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

CME387-NONTRADITIONALMACHININGPROCESS
REGULATION-R-2021
THIRD YEAR-FIFTH SEMESTER
PREPARED BY
Mr.J.BOOPALAN,
AP/MECHANICAL

1
CME 387 NON-TRADITIONAL MACHINING PROCESSES LTPC3003

COURSE OBJECTIVES
1. Toclassifynon-traditionalmachiningprocessesanddescribemechanicalenergybased non-
traditionalmachiningprocesses
2. Todifferentiatechemicalandelectrochemicalenergy-basedprocesses.
3. Todescribethermo-electricenergy-basedprocesses.
4. Toexplainnanofinishingprocesses.
5. Tointroducehybridnon-traditionalmachiningprocessesanddifferentiatehybridnon-traditional
machining processes.
UNIT–I INTRODUCTIONANDMECHANICALENERGYBASEDPROCESSES 9
Introduction-Needfornon-traditionalmachiningprocesses-Classificationofnon-traditionalmachining
processes - Applications, advantages and limitations of non-traditional machining processes - Abrasive
jetmachining,Abrasivewaterjetmachining,Ultrasonicmachiningtheirprinciples,equipment,effectof
process parameters, applications, advantages and limitations.
UNIT-IICHEMICALANDELECTROCHEMICALENERGYBASEDPROCESSES 9
Principles, equipments, effect of process parameters, applications, advantages and limitations of
Chemicalmachining,Electro-chemicalmachining,Electro-chemicalhoning,Electro-chemicalgrinding,
Electro chemical deburring.
UNIT-III THERMO-ELECTRICENERGYBASEDPROCESSES 9
Principles,equipments,effectofprocessparameters,applications,advantagesandlimitationsofElectric
dischargemachining,Wireelectricdischargemachining,Laserbeammachining,Plasmaarcmachining,
Electron beam machining, Ion beam machining.
UNIT–IV NANOFINISHINGPROCESSES 9
Principles,equipments,effectofprocessparameters,applications,advantagesandlimitationsofAbrasive flow
machining – Chemo mechanical polishing, Magnetic abrasive finishing, Magnetorheological finishing,
Magneto rheological abrasive flow finishing.
UNIT–V HYBRIDNON-TRADITIONALMACHININGPROCESSES 9
Introduction-Varioushybridnon-traditionalmachiningprocesses,theirworkingprinciples,equipments,
effect of process parameters, applications, advantages and limitations. Selection and comparison of
different non- traditional machining processes.

TOTAL:45PERIODS TEXT
BOOK:
1. Adithan.M.,“UnconventionalMachiningProcesses”,Atlantic,NewDelhi,India,2009.ISBN13:
9788126910458
2. AnandPandey,“ModernMachiningProcesses”,AneBooksPvt.Ltd.,NewDelhi,India,2019.
REFERENCES:
1. Benedict,G.F.,“Non-traditionalManufacturingProcesses”,MarcelDekkerInc.,NewYork1987.
ISBN-13: 978-0824773526.
2. CarlSommer,“Non-TraditionalMachiningHandbook”,AdvancePublishing.,UnitedStates,2000,
ISBN-13: 978-1575373256.
3. GolamKibria,BhattacharyyaB.andPauloDavimJ.,“Non-traditionalMicromachiningProcesses:
FundamentalsandApplications”,SpringerInternationalPublishing.,Switzerland,2017,ISBN:978-3- 319-
52008-7
4. JagadeeshaT.,“Non-TraditionalMachiningProcesses”,I.K.InternationalPublishingHousePvt. Ltd.,
New Delhi, India, 2017, ISBN-13: 978-9385909122.
5. KapilGupta,NeeleshK.JainandLaubscherR.F.,“HybridMachiningProcesses:Perspectiveson
MachiningandFinishing”,1st edition,Springer International Publishing.,Switzerland,2016,ISBN- 13:
978-3319259208

2
 UNITI
INTRODUCTIONANDMECHANICALENERGYBASED PROCESSES

Part-A(2 Mark questions)

1. Define non- traditional machining processes (or) Unconventional machining process.
(Non/Dec 2021)
2. Whatismeantbyconventionalmachiningprocesses?
3. What are difference between non-traditional machining process and traditional
machining process? (Nov/Dec-2016) (Or) Difference between conventional and
unconventional machining processes. (May/June-2021)
4. State the industrial needs/necessity of Unconventional machining process.(May/June-
2010, 2015,2016,2014, 2021, Nov/Dec -2013,2014,2016,2021)

5. Merits (advantages) of unconventional machining process.(Apr/May-2011),(May/June-

13,16)

6. Whatistheimportanceofunconventionalmachining?(May/June2006)(Nov/Dec2023)
7. List down various mechanical energy based Unconventional machining processes
(Nov/Dec-2004& Apr/May-2010,2021)

8. Whatarethedifferentmachiningcharacteristicswithrespecttowhichthenon- traditional
machining processes can be analysed? (Nov/Dec-2008)

9. Whatarethemachiningcharacteristicswithrespecttowhichthenon-traditionalmachining
process can be analysed? (Nov/Dec 2008) (Apr/ May 2011)

10. Distinguish traditional and non-traditional machining processes. (Apr/May-15,

Nov/Dec-16, Nov/Dec 2019)
11. Mentionthermalenergybasedunconventionalprocesses.(May/June-2012)(May/June-
2013)

12. Whyunconventionalmechanicalmachiningprocessisnotsoeffectiveonsoftmaterials like

aluminium? (Apr/May-2008, Nov/Dec 2019)
13. Hownon-traditionalmachiningProcessisclassified?(Nov/Dec2005,Nov/Dec-2013)
14. List out the limitations of traditional machining processes.(Nov/Dec 2014, Nov/Dec-
2015, May 2019)

3
15. Listtheunconventionalmachiningbasedonchemicalenergy?(Nov/Dec-2015) (May/June-
16)

16. What are thermal energy methods of unconventional machining? (May/ June-
2012,May/Jun-2013)

17. List the unconventional machining process which uses mechanical energy.
(Nov/Dec2004) (Apr/May 2010)

18. Whatarethecharacteristicsof UCMP?(Nov/Dec2004) (Nov/Dec 2007)

19. What are the desirable properties of carrier gas in AJM? (Nov/Dec 2004)
(Apr/May2018)

20. WhatarethedifferenttypesabrasivesusedinAJM?(Apr/May-2010)(Nov/Dec-16)
21. What are the desirable properties of carrier gas in AJM?(Nov/Dec-
2004)(May/June2012,May 2019)

22. Why abrasive jet machining is not recommended to machine ductile materials?
(Apr/May-2011) (Nov/Dec 2014)
23. MentiontheProcessparametersaffectingtheMRRinAJM?(Nov/Dec2013)(Nov/Dec 2018)
(or)WhataretheprocessparametersaffectingthematerialremovalrateinAJM? (Nov/Dec
2019)

24. Whatis theprinciple ofWJM?(Nov / Dec2005) (Apr/May 2018)

25. Listouttheparameterswhichimprovethematerialremovalrateinwaterjet machining.
(Apr/May 2010, Nov/Dec 2007, 2021)

26. Whataretheapplicationsof WJM?(Nov/Dec-16,Apr/May-2015,May/June-16)

27. What is ultrasonic machining? (Or) State the working principle of USM. (Apr/May-
2015,18)(May/June-16)
28. Outlinethepropertiesof tools usedinUSMprocess. (Apr/May-2023)
29. WhatarethecharacteristicsofagoodsuspensionmediaoftheUSMProcess?
(Apr/May2008),(Apr/May2005)(May/June2013)(Nov/Dec 2014)

30. WhataretheDisadvantagesofUSM?OrStatethedemeritsoftheultrasonic machining.

(Nov/Dec 2021)

31. Namethedifferentabrasiveusedin abrasivejetmachiningprocess.(Nov/Dec 2019)

.

4
 PART–B (15-MarksQuestions)

1. Whatistheneedfordevelopmentofunconventionalmachiningprocesses?Explainwith
examples. (Apr/May-2010 & May/June-2007)(Nov/Dec 2013), what are the basic
limitations of unconventional manufacturing processes? Justify the need of
unconventional manufacturingprocess in today’sindustries.(May/June2014,Nov/Dec-
2015, Nov/Dec 2019)

2. Differentiate between conventional and unconventional machining processes. Discuss

the reasons for the development of unconventional machining methods.
(Nov/Dec2014) (May/June-16) Nov/Dec 2023

3. How are the Unconventional machining process classified? (May/June-2012)

Nov/Dec2023

4. AbrasiveJet Machining(AJM)

5. Describe the Principle and Equipment for AJM.(May/June-11, 16)(Nov/Dec-13,15,16)

(Nov/Dec-2004)
6. Explain the principle of AJM. Mention some of the specification. (April/May 2008)
Explainwithneatsketchtheworkingprincipleandparametralinfluenceofabrasivejet
machining.(Nov/Dec 2021)
7. Writeitsadvantagesanddisadvantages.(April/May2010)(April/May 2015.May2019)
(April/May 2012) (May/June 2008, 2014, 2021)

8. WaterJet Machining (WJM)

9. Explaintheprincipleofworkingandequipmentofwaterjetmachiningwithaneat diagram.
(May/June-2012,2021) (Nov/Dec-2008,2014,2015,2018)
10. Ultra-SonicMachining(USM)

11. Explain the working principle and equipment of Ultra Sonic Machining with a neat
sketch.Mentionitsapplications,advantagesandlimitations.(May/June-2016)(Nov/Dec
2013) (May/June 2014) (Nov/Dec -14,15,16) (Nov/Dec 2019) (Apr/May-2023)

12. Explain the significance of non-traditional machining processes in modern manufacturing.

Discuss the key reasons for adopting these processes over conventional machining methods.

5
13. Discuss the classification of non-traditional machining processes. Compare mechanical
energy-based processes like AJM, AWJM, and USM with electrochemical and chemical
machining processes.
14. Describe the principle of Abrasive Jet Machining (AJM). Discuss the role of abrasive
particles, carrier gas, and nozzle design in achieving material removal.
15. Examine the equipment setup required for Abrasive Jet Machining (AJM). Discuss the
components and their functions in the AJM system.
16. Evaluate the effect of process parameters such as abrasive particle size, pressure, and
nozzle distance on the performance of Abrasive Jet Machining (AJM). Provide examples to
illustrate their impact.
17. Discuss the advantages of Abrasive Jet Machining (AJM) over conventional machining
techniques. Highlight specific applications where AJM is preferred.
18. Explain the principle of Abrasive Water Jet Machining (AWJM). Compare AWJM with
pure water jet machining, emphasizing the role of abrasive particles in material removal.
19. Describe the equipment used in Abrasive Water Jet Machining (AWJM). Discuss the
components and their functions in the AWJM system.
20. Explain the principle of Ultrasonic Machining (USM). Discuss how ultrasonic vibrations
facilitate material removal in USM.

PART–C(15-MarksQuestions)

1. Explain the rationale behind the development and adoption of non-traditional machining
processes. Discuss the advantages these processes offer over conventional machining
methods, with a focus on AJM, AWJM, and USM.
2. Discuss the classification of non-traditional machining processes. Compare and contrast
mechanical energy-based processes like AJM, AWJM, and USM with electrochemical and
chemical machining processes, highlighting their unique characteristics and applications.
3. Evaluate the principles of Abrasive Jet Machining (AJM). Discuss the role of abrasive
particles, carrier gas, and nozzle design in achieving effective material removal. Provide a
detailed explanation of the process mechanisms involved.
4. Describe the equipment setup required for Abrasive Jet Machining (AJM). Discuss the
components and their functions within the AJM system, emphasizing their roles in
controlling process parameters and achieving desired outcomes.
5. Analyze the effect of key process parameters such as abrasive particle size, pressure, nozzle
diameter, and abrasive flow rate on the performance and efficiency of Abrasive Jet
Machining (AJM). Illustrate your answer with practical examples.

6
6. Discuss the advantages of Abrasive Jet Machining (AJM) in precision machining
applications. Provide examples where AJM is particularly suitable, considering factors such
as material type, surface finish requirements, and geometric complexity.
7. Explain the principles and operational mechanisms of Abrasive Water Jet Machining
(AWJM). Compare AWJM with pure water jet machining, focusing on how the inclusion of
abrasive particles enhances material removal capabilities.
8. Describe the equipment setup and components used in Abrasive Water Jet Machining
(AWJM). Discuss their functions and contributions to process control and optimization,
ensuring efficient material cutting and shaping.
9. Analyze the impact of process variables such as water pressure, abrasive flow rate, standoff
distance, and traverse speed on the cutting performance and surface quality in Abrasive
Water Jet Machining (AWJM). Provide strategies for optimizing these parameters.
10. Discuss the advantages of Abrasive Water Jet Machining (AWJM) in cutting various
materials, including metals, composites, and ceramics. Evaluate its capabilities in terms of
thickness cutting, intricate shape machining, and heat-sensitive material processing.

7
 UNITII

Part-A
1. Statetheprincipleofchemical machiningprocess
2. WhataretheparametersthataffecttheMRRinchemicalmachining?(May/June-2012)
3. Statetheadvantagesofchemical machining.(May/June-2007)
4. Whatismeantbyetchfactor?(Apr/May-2008) ?(Nov/Dec2022)
5. Defineelectro chemical machining(ECM)?(Nov/Dec2004)Nov/Dec2023
6. Writethe Faraday’sfirstlaw of electrolysis?
7. WritetheFaraday’ssecondlawofelectrolysis?(May/June-2021)
8. Whatarethematerialsusedtomaket
he
toolelectrodeinECM?(Apr/May-
2005)
9. WritethedifferencebetweenCh
emicalMachiningandElectro
ChemicalMachining.
(Apr/May-2011)

10. What are the main functionsof electrolysis in the ECM? (May/June-2006 & Nov/Dec-
2006) (May/June 2014) (Nov/Dec 2014)

11. usedintheECM?(Nov/Dec- 13)(May/June-16)

12. Whataretheelectrolytescommonlyusedin ECM?(Apr/May-2005,May/June-2007)

13. WhatarethedifferenttypesECMoperations?(May/June-2021)
14. Whatistheself-adjustingfeaturein ECM?(Apr/May-2008)
15. Please identify the principle of ECM. How does it differ from electroplating? (Nov/Dec-
2008, May/June-16, Apr/May-2010)
16. Whataretheadvantagesof ECM?(Nov/Dec-13)(May/June-16)(Apr/May-2023)
17. Whatarethelimitationsof ECM?(Nov/Dec-2007)(Nov/Dec-2013)(May/June-16)
18. Whataretheapplicationsof ECM?(Nov/Dec2006)
19. Definemaskinginelectrochemicalmachining.(Nov/Dec2021)

20. List out the types of etchants used in chemical machining. (or) What are the etchants in
chemical machining process? (Nov/Dec-15,2021)
21. ListthecommonlyusedmaskantinChemical MachiningProcess. (May/June2013)
22. Whataretheimportantfunctionsofabrasiveparticlesusedin ECG?
23. Why the life of Electro Chemical Grinding (ECG) wheel is much higher than
Conventional grinding wheel? (Apr/May-2011) (Nov/Dec 2022)
24. ListtheapplicationsofElectroChemicalHoning(ECH).(Apr/May-2010,Apr/May-2015)
25. WritetheformulaforfindingtheMRRinECGprocess.(May/June2013)

8
 PART–B (15-MarksQuestions)
1. Explain the principle of working, equipment, Applications, Advantages and drawbacks
ofchemicalmachiningandchemicalmilling(May/June-13,16)(Nov/Dec-13,15Apr/May- 15)
(Apr/May-2023)

2. Explaintheprincipleofworking,equipment’s,Applications,Advantagesanddrawbacks of
Electro chemical machining (May/June-14,16, 21)(Nov/Dec-16) (Apr/May-2015)
(Nov/Dec 2021)

3. Explaintheprinciple,working,equipment’sandApplicationsofElectroChemicalGrinding
(May/June-10, 12, 15, 16, 21), (Nov/Dec-13, 15, 16) (Nov/Dec 2021) (Apr/May-
4. 2023)
5. BrieflydiscussElectroChemicalDeburringprocess?(Nov/Dec 2014)

6. Explain the principle of Chemical Machining (CHM). Discuss the equipment used, key
process parameters, and the types of materials suitable for CHM. Evaluate its advantages,
limitations, and applications in manufacturing.
7. Describe the working principle of Electrochemical Machining (ECM). Discuss the role of
electrolyte, electrodes, and process parameters such as voltage, current density, and
electrolyte flow rate. Provide examples of specific components produced using ECM.
8. Explain the working mechanism of Electrochemical Grinding (ECG). Compare it with
conventional grinding processes in terms of material removal rate, surface finish, and tool
wear. Discuss its advantages, limitations, and applications in precision machining.
9. Describe the process of Electrochemical Deburring (ECD). Discuss its principle, equipment
used, process parameters, advantages, and limitations. Provide examples of components
that benefit from ECD in the manufacturing industry.
10. Compare and contrast Chemical Machining (CHM) and Electrochemical Machining
(ECM). Discuss their principles, equipment, applications, advantages, and limitations.
Provide specific examples to illustrate their differences.
11. Analyze the impact of electrolyte composition and concentration on the performance of
Electrochemical Machining (ECM). How do these factors affect material removal rate and
surface quality?
12. Discuss the environmental and safety considerations of using electrolytes in Electrochemical
Machining (ECM) and Electrochemical Deburring (ECD). How can these considerations be
mitigated in industrial applications?
13. Evaluate the role of abrasives in Electrochemical Grinding (ECG). How do abrasive
particles enhance material removal and surface finishing capabilities? Discuss the effects of
abrasive particle size and concentration on ECG performance.
9
14. Explain the principle of selective dissolution in Chemical Machining (CHM). Discuss how
process parameters such as etchant concentration and temperature influence the etching
process and surface finish.
15. Discuss the advancements in Electrochemical Machining (ECM) technology. How have
these advancements improved the precision, efficiency, and range of applications of ECM in
modern manufacturing?
16. Analyze the challenges associated with achieving high aspect ratio features using
Electrochemical Machining (ECM). Discuss strategies and advancements in tool design and
process control to overcome these challenges.
17. Explain the role of inter-electrode gap in Electrochemical Machining (ECM). How does the
gap distance affect machining accuracy and surface finish?
18. Explain the principle of material removal in Electrochemical Deburring (ECD). How does
ECD effectively remove burrs from machined components? Discuss its advantages over
mechanical deburring methods.
19. Discuss the role of computer numerical control (CNC) and automation in enhancing the
precision and repeatability of Electrochemical Machining (ECM). How does CNC
integration improve ECM process control and efficiency?
20. Discuss the future trends and potential developments in chemical and electrochemical
energy-based processes. How are emerging technologies and materials influencing the
evolution of these machining techniques?

PART–C(15-MarksQuestions)

1. Explain the principle of Chemical Machining (CHM) and discuss its applications in modern
manufacturing. Evaluate the environmental and economic implications of CHM compared
to conventional machining methods.
2. Discuss the working principle and equipment used in Electrochemical Machining (ECM).
Analyze the role of electrolyte composition, current density, and tool feed rate in achieving
precise machining outcomes. Provide examples of components where ECM is preferred.
3. Describe the process parameters and their effects on the performance of Electrochemical
Honing (ECH). Compare ECH with traditional honing processes in terms of surface finish,
dimensional accuracy, and process efficiency.
4. Explain the concept of Electrochemical Grinding (ECG). Discuss its advantages over
conventional grinding processes and evaluate its limitations. Provide examples of
applications where ECG is beneficial.

10
5. Discuss the mechanisms involved in Electrochemical Deburring (ECD). Evaluate the
effectiveness of ECD in removing burrs from machined components. Compare ECD with
mechanical deburring methods.
6. Compare and contrast the applications of Chemical Machining (CHM) and Electrochemical
Machining (ECM). Discuss how these processes complement each other in modern
manufacturing scenarios.
7. Analyze the factors influencing the material removal rate and surface integrity in
Electrochemical Machining (ECM). Discuss strategies for optimizing ECM processes to
achieve desired machining outcomes.
8. Evaluate the role of process automation and computer numerical control (CNC) in
enhancing the precision and efficiency of Electrochemical Machining (ECM). How does
automation improve process control and repeatability in ECM?
9. Discuss the advancements in Electrochemical Machining (ECM) technology. How have
innovations in tool materials, electrode design, and electrolyte formulations contributed to
improving ECM capabilities?
10. Examine the environmental sustainability of Electrochemical Machining (ECM) and
Electrochemical Deburring (ECD) processes. Discuss strategies for reducing environmental
impact and enhancing process efficiency in electrochemical machining operations.

11
 UNIT– III
THERMALANDELECTRICALENERGYBASEDPROCESSES
PartA(2Marks)
1. WhatistheworkingprincipleofElectricaldischarge machiningprocess?
2. HowthetoolmaterialsareclassifiedinEDM?(May/June2007)
3. Briefthematerialremovalmechanismin EDMprocess.(Apr/May-2023)
4. Definetool wearratio.Or Definethe tool wearratio in EDM.(Nov/Dec2022)
5. MentionfewtypesofpowersupplycircuitsusedinEDM?(Nov./Dec.2007,2008, May/June-
2021)

6. Whatthedielectricfluidscommonlyusedin EDM?
What kind of dielectric fluid is commonly used in wire electric discharge machining?
Nov/Dec 2023

7. WhatarethevariousmaterialsofwhichelectrodearemadeforEDMprocessandwhat are
their advantages? (Nov/Dec 2021)
8. Whatarethedesirablepropertiesofgooddielectricfluid?(Nov/Dec2005),(Apr/May 2010)

9. WhatarethefunctionsofanadoptivecontrolsystemusedforEDM?(April/May2008) (May/
June 2012)
10. Whatis theprinciple ofoperation of wire-cut EDMprocess?(Nov/Dec2008)
11. StatethedifferencebetweenthewirecutEDMandEDM.(Nov/Dec 2006)
12. WhatistheprincipleofLBM?(Nov/Dec-2005,15)
13. Statethecharacteristics of laserbeam.(Nov/Dec-2006)(Nov/Dec-13)
14. Statethetypesof lasers usedin manufacturingoperation.(Nov/Dec 2021)
15. Whatismeantbylaser beamdrilling?(Apr/May-15)
16. Whatdoyoumeanbyplasma?(Nov/Dec-2016)
17. Whatis theprincipleofPAM? (May/Jun-2009), (May/Jun-2016)
18. Canyou machineelectricallynon-conductivematerialsby PAM?Justifyyouranswer.
(Apr/May-2011)
19. What is transferable and non-transferable arc in Plasma Arc Machining? (Nov/Dec-
2004)(May/Jun-2012)
20. Listanytwogasesusedin PAM. (Apr/May-2005)
21. WritetheadvantagesofPlasmaArc Machining?(May/Jun-14)
22. Whatarethelimitationsof EBM?(Nov/Dec-2004)(Apr/May-2023)

12
23. ContrastLBMandEBM.(Nov/Dec-2005),(May/Jun2014)(Nov/Dec 2016)
24. WhyvacuumisneededinElectronBeamMachiningProcesses?(May/Jun-2009),
(Apr/May-2011)

25. WhatarethetechniquesusedforcontrollingbeaminEBMProcess(May/Jun-
2016,Apr/May-2015)

13
 PART-B(13Marks )

1. Explain the EDM process and list its advantages, disadvantages and applications
(Nov/Dec-2008, 2016), (Apr/May-20011, 2014, 2016) (Nov/Dec 2021)

2. ExplaintheWirecutEDMandlistitsadvantages,disadvantagesandapplications (Apr/May-
2010, Nov/Dec-16) (May/Jun-14, 16) (Nov/Dec- 15) (Apr/May-15)
3. TravellingWireElectro-DischargeMachining(TWEDM)orWirecutEDM

4. OutlinewirecutEDMwithaneedsketchandexplainitssignificantprocess parameters for

good surface finish. (Apr/May-2023)

5. ExplaintheprocessparameterswhichgoverntheEDM/WirecutEDMprocess.(Nov/Dec-
2013, May/June-2021) (Nov/Dec 2021

6. Discussindetailaboutthethermalfeatureandanalysisoflaserbeammachining
Thermal Feature and Analysis of Laser Beam Machining:

7. What is the principle of plasma arc machining? What are the two stages in which
theprocessofmaterialremovalisaffected?Whatisthemainindustrialapplicationof plasma
cutting systems?(Nov/Dec-08, 15) (Apr/May-2015) (May/June-2021) Introduction

8. Explain the principle, equipment, working, advantages, limitations and applications of

Electron Beam Machining [EBM].(Apr/May-2010),(Apr/May-2011), (May/Jun-
2012)&(May/Jun-2013) (Nov/Dec-14,15)(Apr/May-2015)
9. Compare and contrast the applications advantages and limitations of wire electric
discharge machining and electric discharge machining.Nov/Dec 2023
10. Explain the differences between laser beam machining and electron beam machining
in termsoftheprinciples,equipmentusedapplicationunderpotentialchallenges.Nov/
Dec2023

11. Describe the Wire Electric Discharge Machining (WEDM) process. How does it differ from
conventional EDM? Discuss its applications and advantages in precision machining.
12. Discuss the Ion Beam Machining (IBM) process. Explain its principle, equipment, and
process parameters, and evaluate its advantages and limitations in microfabrication.
13. Compare and contrast the applications, advantages, and limitations of EDM and WEDM.
Provide examples of specific components that benefit from these processes.
14. Evaluate the role of laser parameters, such as power, wavelength, and beam quality, in
Laser Beam Machining (LBM). How do these parameters affect the machining process and
outcome?

14
15. Discuss the environmental and safety considerations of using Electron Beam Machining
(EBM). How do these considerations compare to those of other thermo-electric energy-
based processes?
16. Explain the challenges and solutions in machining heat-resistant superalloys using EDM
and WEDM. Provide examples of their applications in the aerospace industry.
17. Discuss the advancements in Laser Beam Machining (LBM) technology. How have these
advancements improved its precision, efficiency, and range of applications
18. Evaluate the effectiveness of Plasma Arc Machining (PAM) in cutting thick metal plates.
electric energy-based processes overcome these limitations. Provide examples of specific
applications.
19. Discuss the integration of automation and computer numerical control (CNC) in EDM and
WEDM. How does automation improve the efficiency and precision of these processes?
20. Evaluate the role of thermo-electric energy-based processes in the medical device industry.
Discuss specific examples of devices and components manufactured using these processes.

Part C (15 Marks )

1. Explain the working principle, equipment, process parameters, advantages, and limitations
of Electric Discharge Machining (EDM). Provide examples of its applications in the
manufacturing industry.
2. Discuss in detail the Wire Electric Discharge Machining (WEDM) process. How does it
differ from conventional EDM? Evaluate its applications, advantages, and limitations, with
specific examples.
3. Analyze the principles, equipment, and process parameters of Laser Beam Machining
(LBM). Discuss its advantages, limitations, and applications in various industries such as
aerospace, automotive, and medical.
4. Describe the Plasma Arc Machining (PAM) process. Explain the working mechanism, key
process parameters, and provide a comprehensive evaluation of its advantages, limitations,
and industrial applications.
5. Explain the Electron Beam Machining (EBM) process in detail. Discuss the principles,
equipment used, process parameters, and evaluate its advantages, limitations, and
applications, particularly in the electronics and aerospace industries.
6. Discuss the Ion Beam Machining (IBM) process. Provide a detailed explanation of its
principles, equipment, process parameters, advantages, limitations, and applications,
especially in microfabrication and nanotechnology.
7. Compare and contrast EDM, WEDM, and LBM. Discuss the differences in their principles,
equipment, process parameters, advantages, limitations, and typical applications. Provide
specific examples to illustrate your points.
15
8. Evaluate the role of dielectric fluids in EDM. Discuss the types of dielectric fluids, their
properties, and how they affect the machining performance and surface finish. Provide
examples of different dielectric fluids used in industrial applications.
9. Analyze the impact of process parameters such as power, wavelength, beam quality, and
cutting speed on the performance and outcome of Laser Beam Machining (LBM). Discuss
how these parameters can be optimized to achieve desired results.
10. Discuss the advancements and future trends in thermo-electric energy-based machining
processes. Evaluate how emerging technologies such as AI, machine learning, and
automation are influencing the efficiency, precision, and applications of these processes.
Provide specific examples.

16
 UNITIV
NANOFINISHINGPROCESSES
1. Writetheprincipleofabrasiveflow machining process.
2. Listoutthetypesofabrasiveflow machining processes.
3. DefineonewayAFM.
4. Listout theAdvantagesofOne-way AFM:
5. DefinetwowayAFM.
6. WhataretheAdvantagesofTwo-wayAFM?
7. Defineorbital AFM.
8. ListouttheelementsofAFM.
9. Listoutthetwoaimsof ToolingforAFMmachine.
10. Writethe processparameters of abrasive flowmachining. (May/June-2021)
11. WritetheworkingprincipleofChemomechanicalpolishing.
What is chemo-mechanical polishing? Nov/Dec 2023

12. Whataretheslurry usedin CMPProcesses?

13. Listouttheapplicationsof CMP Process.

14. Identifytheapplicationsofthechemo-mechanicalpolishingprocess.(Apr/May-2023)

15. Write the working principles of magnetic abrasive finishing process. State the principle of
magnetic abrasive finishing process. (Nov/Dec 2022)

16. List out the applications of Magnetic abrasive finishing processes.

Statetheapplicationsofmagneticabrasivefinishing.Nov/Dec2023

17. Whatisthepurposeofabrasivesinthemagneticabrasivefinishingprocess?(Apr/May- 2023)

18. Writedowntheprincipleofmagneto rheologicalfinishing.(Nov/Dec 2021)

19. DrawthediagramforMagnetorheologicalfinishing.

20. Statethematerialspreferredasanabrasiveparticleanditssizeinnanofinishing. Nov/Dec

2021)

21. Definethemagneto-rheologicaleffect.(Nov/Dec 2022)

22. What type of equipment is used in Magnetic Abrasive Finishing?

23. Mention one advantage of Magneto Rheological Abrasive Flow Finishing (MRAFF).
24. What role do chemical agents play in Chemo Mechanical Polishing?
25. Describe one limitation of Magnetic Abrasive Finishing (MAF).

17
 PART-B(13Marks)

AbrasiveFlowMachining:

1. ExplainAbrasiveflowmachiningprocessprinciples,working,processparameters,advantage
, disadvantage and application in details. Nov/Dec 2023
2. Discusstheabrasiveflowmachiningwithaneatillustrationandmentionitsapplications.
(Apr/May-2023)

3. Explain Chemo-Mechanical Polishing process principles, working, process parameters,

advantage, disadvantage and application in details. (July 2021) (Nov/Dec 2021)

4. ExplainMagneticabrasivefinishingprocessprinciples,working,processparameters,
advantage, disadvantage and application in details. (Nov/Dec 2021) (Apr/May-2023)

5. Explain Magneto rheological finishing process principles, working, process parameters,

advantage, disadvantage and application in details. Nov/Dec 2023

6. ExplainMagnetorheologicalabrasiveflowfinishingprocessprinciples,working,process
parameters, advantage, disadvantage and application in details (July 2021)

7. Discuss the importance and emergence of nano finishing processes in detail. (Nov/Dec
2021)

8. Explain the working principle and equipment used in Abrasive Flow Machining (AFM).
Discuss its advantages, limitations, and applications.
9. Discuss the process parameters in Chemo Mechanical Polishing (CMP) and their effects on
the final surface finish.
10. Describe the working mechanism of Magnetic Abrasive Finishing (MAF). What are its key
advantages and typical applications?
11. Explain how Magnetorheological Finishing (MRF) achieves high precision in surface
finishing. Include a discussion on equipment and process parameters.
12. Discuss the principle, equipment, and applications of Magneto Rheological Abrasive Flow
Finishing (MRAFF). How does it differ from conventional AFM?
13. Analyze the factors affecting the performance of AFM. How can the process parameters be
optimized to improve surface quality?
14. Evaluate the advantages and limitations of CMP in the semiconductor industry. Provide
examples to illustrate your points.
15. Compare and contrast the applications and limitations of MAF and MRF in achieving
nanofinishing.
18
16. Explain the role of abrasive particles in AFM. How does the choice of abrasive material
impact the finishing process?
17. Discuss the integration of magnetic fields in MAF. How does the magnetic field influence
the finishing process and outcomes?
18. Describe the key components of a CMP setup. How do chemical agents and mechanical
actions work together to achieve a polished surface?
19. Examine the applications of MRF in the optics industry. What are the advantages of using
MRF over other finishing techniques?
20. Discuss the challenges associated with AFM when dealing with complex geometries. How
can these challenges be mitigated?
21. Analyze the environmental and economic considerations of using CMP in manufacturing.
22. Explain the significance of magnetorheological fluids in MRAFF. How do these fluids
enhance the finishing process?
23. Discuss the impact of process parameters such as pressure, temperature, and abrasive
concentration on the performance of AFM.
24. Evaluate the role of MAF in the automotive industry. Provide examples of specific
components that benefit from this finishing process.
25. Explain how MRF can be used to achieve ultra-smooth surfaces on high-precision
components.
26. Discuss the advancements in AFM technology. How have these advancements improved the
efficiency and effectiveness of the process?
27. Analyze the role of hybrid nanofinishing processes that combine MAF and CMP. What are
the potential benefits and applications of such hybrid processes?

PART C (15 Marks)

1. Explain the principle, equipment, and process parameters of Abrasive Flow Machining
(AFM). Discuss its applications, advantages, and limitations in detail.
2. Describe the working mechanism of Chemo Mechanical Polishing (CMP). Analyze the
factors affecting its performance, including the role of chemicals and abrasives, and discuss
its applications in various industries.
3. Discuss in detail the principles, equipment, and process parameters of Magnetic Abrasive
Finishing (MAF). Evaluate its advantages, limitations, and applications, particularly in the
aerospace and automotive industries.
4. Explain the concept of Magnetorheological Finishing (MRF). Describe the equipment used,
the process parameters involved, and the advantages and limitations of this technique.
Provide examples of its applications in the optics industry.

19
5. Analyze the principles and working mechanism of Magneto Rheological Abrasive Flow
Finishing (MRAFF). Discuss how it combines the features of AFM and MRF, and evaluate
its effectiveness in achieving high-precision surface finishes.
6. Discuss the impact of process parameters such as abrasive particle size, flow rate, and
pressure on the performance of AFM. Provide examples of how these parameters can be
optimized to achieve desired surface finishes.
7. Evaluate the role of CMP in the semiconductor manufacturing industry. Discuss its
advantages and limitations, and provide examples of specific components and devices that
benefit from this finishing process.
8. Compare and contrast the applications, advantages, and limitations of MAF and MRF.
Discuss how these processes can be used to achieve nanofinishing on different types of
materials and components.
9. Examine the environmental and economic considerations of using nanofinishing processes
such as AFM, CMP, and MAF. Discuss potential strategies for mitigating environmental
impact and improving cost-effectiveness.
10. Discuss the advancements and future trends in nanofinishing processes. Evaluate the
potential impact of emerging technologies such as AI, machine learning, and automation on
the efficiency and precision of these processes.

20
 UNIT– V
HybridNon-TraditionalMachiningProcesses
PART- A
(2 MARKS)
1. Whatis a hybrid process?
2. Listtheneedsforhybridmachiningprocesses. (April/May2023)
3. HowmaterialremovaltakesplaceinElectroChemicalSpark Machining?
4. WritedownthechemicalreactioninECSM?
5. WhataretheapplicationsofECSM?
6. Whydowechooseelectricdischargediamondgrinding?
7. Namethedielectricfluidsusedin EDDG.
8. Namethe twoconfigurationsusedinEDDG.
9. Listthe advantagesofEDDG.
Writetheadvantagesofhybrid non-traditionalmachiningprocesses. Nov/Dec2023
10. DefineFaraday`slaw ofelectrolysis.
11. Listthefunctionof electrolytein ECMM.
12. Whysodiumnitrateis moreadvantageinECMM?
13. ListtheapplicationofECMM.
14. Listthetypesof thermaladvancedmicromachiningprocesses.
Listtwoexamples of hybrid non-traditionalmachiningprocesses.Nov/Dec2023
15. Nametheworkpiecematerialsusedin EDMM.
16. Whatarethemain componentsofEBMM?
17. ListtheapplicationsofEBMM?
18. Whatarethetypes of laserusedinLBMM?
19. Writedownthereaction thattakesplaceinECMM.
20. ListtheapplicationsofLBMM?
21. DefineMicromachining.
22. Whatarethemechanicaladvancedmicro machiningprocesses?
23. Detailthetypeof nozzle usedin AJMM.
24. Detailthe focustubeusedinAJMM.
25. Listthefunctionsofslurryusedin USMM.
26. Mentionthelimitationsofnon-traditionalmachiningprocess.(Apr/May-2023)

21
 PART-B &C (13&15MARKS)

1. Explain the benefits of hybrid unconventional machining technologies and elaborate on

the challenges and opportunities. (Apr/May-2023)
2. Whilehybridnon-traditionalmachiningprocessesoffermanyadvantages,theyalsocome
withspecificchallenges.Discusstheselimitationsandpotentialsolutionstoaddressthem.
Nov/Dec 2023

3. ExplainwithneatsketchesofElectrochemicalSparkMachining.Explain thevarious
applications of hybrid non traditional machining processes across industries. Nov/Dec
2023

4. Explainworkingprincipleofelectricaldischargediamondgrindingwithneatsketch.

5. ExplaintheworkingofAbrasiveWaterJetMicro Machining.

6. ExplainEDMMprocesswithneatsketch.

7. ExplaintheprincipleofElectronBeamMicroMachiningProcess

8. Describe anyone laser assisted machining process with constructional detail. (Apr/May-
2023)

9. Explaintherecentdevelopmentsinnon-traditionalmachiningprocesses.(Nov/Dec2021)
10. Explaintheworkingprincipleof3Dprintingtechnologyfortheproductionofparts.(July
2021)

11. Compare and contrast the principles of operation between abrasive jet machining,
abrasive water jet machining and ultrasonic machining. Nov/Dec 2023
12. Explain in detail the working principle, equipment, and applications of Electrochemical
Grinding (ECG).
13. Discuss the advantages and limitations of combining Ultrasonic Machining (USM) with
Electrical Discharge Machining (EDM).
14. Describe the process parameters affecting Abrasive Water Jet Machining (AWJM) and
their impact on machining performance.
15. Compare and contrast the mechanisms of material removal in Laser-Assisted Machining
(LAM) and Plasma Arc Machining (PAM).
16. Evaluate the benefits of using hybrid machining processes in the aerospace industry,
providing specific examples.

22
17. Analyze the role of dielectric fluids in EDM, including types, properties, and their effects on
machining efficiency.
18. Explain the hybrid process combining Electrical Discharge Machining (EDM) and
Electrochemical Machining (ECM) with examples.
19. Discuss the applications and limitations of Chemical-Assisted Laser Machining (CALM).
20. Describe how hybrid processes improve machining performance compared to traditional
machining methods. Provide examples.
21. Explain the significance of tool wear in hybrid machining processes and methods to mitigate
it.
22. Discuss the role of abrasive particles in Abrasive Jet Machining (AJM) and factors affecting
their performance.
23. Evaluate the impact of hybrid machining processes on the surface integrity of machined
components.
24. Describe the working principle, advantages, and applications of Ultrasonic Vibration
Assisted Turning (UVAT).
25. Analyze the effects of laser power and cutting speed on the performance of Laser Beam
Machining (LBM).
26. Explain the considerations for selecting a hybrid machining process for manufacturing
medical implants.
27. Discuss the challenges associated with machining advanced composite materials using
hybrid processes.
28. Evaluate the environmental impact of various hybrid non-traditional machining processes
and suggest ways to mitigate them.
29. Compare the material removal rates and precision of EDM, ECM, and their hybrid process.
30. Discuss the future trends and potential developments in hybrid non-traditional machining
technologies.
31. Explain the significance of process parameter optimization in hybrid machining processes
for achieving desired outcomes.

PART C(15 Marks)

1. Explain the concept of hybrid non-traditional machining processes and discuss their
significance in modern manufacturing. Provide examples of at least three hybrid processes
and their applications.

23
2. Discuss in detail the working principle, equipment, advantages, limitations, and
applications of Electrical Discharge Machining (EDM) combined with Ultrasonic
Machining (USM). How does this hybrid process enhance machining performance?
3. Analyze the role of laser technology in hybrid machining processes. Explain the working
principles, advantages, and limitations of Laser-Assisted Machining (LAM) and its
applications in different industries.
4. Describe the process parameters that significantly impact Abrasive Water Jet Machining
(AWJM). Discuss how these parameters can be optimized in a hybrid process involving
AWJM and another non-traditional machining technique.
5. Evaluate the advantages and limitations of combining Electrochemical Machining (ECM)
with other non-traditional machining processes. Provide examples of specific hybrid
processes and their industrial applications.
6. Discuss the environmental and economic implications of hybrid non-traditional machining
processes. Compare these implications with those of conventional machining techniques.
Provide examples to support your analysis.
7. Explain the working principle, advantages, and applications of the hybrid process
combining EDM and ECM. How does this combination address the limitations of individual
processes?
8. Analyze the challenges and solutions in machining advanced composite materials using
hybrid non-traditional machining processes. Discuss specific examples and case studies
where hybrid processes have been successfully implemented.
9. Discuss the impact of process parameters on the surface quality and dimensional accuracy
in hybrid non-traditional machining processes. Provide examples of how parameter
optimization can enhance machining outcomes.
10. Examine the future trends and potential advancements in hybrid non-traditional machining
technologies. Discuss how emerging technologies, such as AI and machine learning, can be
integrated into hybrid machining processes to improve efficiency and precision.

24
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139
Reg.No.:

QuestionPaperCode:40813

B.E./B.Tech.DEGREEEXAMINATIONS,NOVEMBER/DECEMBER2021.

Sixth/SeventhSemester

MechanicalEngineering

ME8073—UNCONVENTIONALMACHININGPROCESSES

(Common to Manufacturing Engineering/Mechanical

Engineering(Sandwich)/Mechanical and Automation Engineering/Production
Engineering)

(Regulations2017)

Time:Threehours Maximum:100marks
AnswerALLquestions.

PARTA—(102=20marks)

1. Listouttheparameterswhichimprovesthematerialremovalrateinwaterjet
machining.

2. Statethedemeritsoftheultrasonicmachining.

3. Listouttheelectrodematerialsusedinelectricdischargemachining.

4. Statethetypesoflasersusedinmanufacturing operations.

5. Listoutthetypeofetchantsusedinchemicalmachining.

6. Definemaskinginelectrochemicalmachining.

7. Statethematerialspreferredasanabrasiveparticleanditssizeinnano finishing.

8. Writedowntheprincipleofmagnetorheologicalfinishing.

9. Definenontraditionalmachiningprocesses.

10. Statethenessecityofnontraditionalmachiningprocesses.

140
 PARTB—(513=65marks)

11. (a)Explain with neat sketch the working principle and the parametral
influence of abrasive jet machining.

Or

(b) Discussthephysicsofultrasonicwaves.Explainthegenerationofwaves and

machining process.

12. (a)DiscusstheconsiderationsinEDMtooldesign.Explainindetailabout
thetoolparametersanditsroleinmaterialremovalrateandsurface finish.

Or

(b) Distinguishandexplainthehighenergymachiningprocesses.

13. (a) Distinguishand explainthechemicalmachiningandelectrochemical

machining processes.

Or

(b) Listoutandexplainthespecificadvancementsinelectrochemicalmachining
processes.

14. (a) Explaintheworkingprincipleandthetoolingofchemo-mechanicalpolishing.

Or

(b) Distinguishbetweenthemagneticabrasiveandmagnetorheological finishing

processes and explain about both the processes.

15. (a) Explaintherecentdevelopmentsinnontraditionalmachiningprocesses.

Or

(b) Discussthefactorstobeconsidered,whileselectingthenontraditional
machining processes.

PARTC—(115=15marks)

16. (a) Explain the energy and cost efficient non-traditional machining
processesthat call be used for profile cutting in detail.

Or

(b) Discusstheimportanceandemergenceofnanofinishingprocessesin detail.

———————

2 40813

141
 Reg.No.:

QuestionPaperCode:X10683
B.E./B.Tech.DEGREEEXAMINATIONS,NOV/DEC2020ANDAPRIL/MAY2021
Sixth/SeventhSemester
MechanicalEngineering
ME8073–UNCONVENTIONALMACHININGPROCESSES
(CommontoManufacturingEngineeringMechanicalandAutomationEngineeringand
Production Engineering)
(Regulations2017)

Time:ThreeHours Maximum:100Marks
AnswerALLquestions
PART–A (10×2=20Marks)

1. Listdownvariousmechanicalenergybasedunconventionalmachiningprocesses.

2. WritetheelementsandcharacteristicsofUSM.

3. ListtheprocessparametersofPAM.

4. MentionafewvarietiesofpowersupplycircuitscommonlyusedinEDM.

5. WhatarethedifferenttypesECMoperations?

6. WritetheFaraday’ssecondlawofelectrolysis.

7. ClassifythedifferenttypesofAdvancedMachiningProcessesbasedondifferent criteria.

8. Writetheprocessparametersofabrasiveflowmachining.

9. Needforthedevelopmentofunconventionalmachiningmethods.

10. Differencebetweenconventionalandunconventionalmachiningprocesses.

PART–B (5×13=65Marks)
11. a)Discuss in detail about the AJM process variables that influence the rate of
material removal and accuracy in the machining. (13)
(OR)

142
X10683

b) ExplaintheworkingprincipleandprocessparametersinWJMprocesses.List
theapplications,advantagesandlimitationsofWJM. (13)

12. a)DiscusstheprocessparametersofEBMandtheirinfluenceonmachiningquality. (13)

(OR)
b) ExplaintheprocessparameterswhichgoverntheEDM/wireEDMprocess.(13)

13. a)Explaintheprincipleofworking,equipment’sandApplicationsofElectro Chemical

Grinding. (13)
(OR)
b) Describetheworkingprincipleandelementsofchemicalmachining.Whatare
thefactorsonwhichtheselectionofaresistforuseinchemicalmachining?(13)

14. a)Explaintheprincipleofworking,equipment’sandapplicationsofchemo-mechanical
polishing. (13)
(OR)
b) Explain the process parameters which govern the magneto rheological abrasive
finishing process with neat sketch. (13)

15. a)Explain the reasons for the development of Unconventional Machining Process.
Discussaboutthecriteriarecommendedinselectionoftheseprocesses. (13)
(OR)
b) Explain the working principle of 3D printing technology for the production ofparts.
(13)

PART–C (1×15=15Marks)

16. a)What is the principle of plasma arc machining ? What are the two stages in
which the process of material removal is affected ? What is the main industrial
application of plasma cutting systems ?
(OR)
b) How will you carry out the analysis for optimization of metal removal rate in
EDM process ? What are the steps that are to be adopted in sequence while
applying the linear programming technique to optimize the metal removalrate
in EDM process ?

143