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Introduction to Mechanical Micro Machining

Assignment- Week 1
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

What is correct in context of miniaturization?

a) Low accuracy and sensitivity

b) High cost to performance ratio

c) Faster device

d) High energy required for excitation

Correct Answer: (c)

Detailed solution:
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QUESTION 2:

What is MCU?

a) Mechanical Control Unit

b) Mechanical Central Unit

c) Machine Control Unit

d) Machine Central Unit

Correct answer: (c)

Detailed solution:
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QUESTION 3:

Which of the following is a hybrid machining process?

a) ECM

b) EDM

c) LBM

d) ECDM

Correct answer: (d)

Detailed solution: Electrochemical discharge machining (ECDM), which is a combination of ECM

and EDM, is known as a hybrid machining process.

QUESTION 4:

Which of the following is a material removal process?

a) Forming

b) Welding

c) 3D Printing

d) Grinding

Correct Answer: (d)

Detailed Solution: Forming, welding, and 3D printing are mass-containing, joining, and additive

processes, respectively. Grinding removes the material, so it is a material removal process.

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QUESTION 5:

The feature tolerance of an object is 0.001mm and its size is 10 mm, then its relative accuracy will

be

a) 0.01

b) 104

c) 10.001

d) 10-4

Correct Answer: (d)

Detailed Solution: Relative accuracy = Tolerance / Object size

Relative accuracy = (0.001/10) = 0.0001 = 10-4

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QUESTION 6:

Most widely used workpiece material in MEMS based process is

a) Steel

b) Silicon

c) Copper

d) Aluminum

Correct answer: (b)

Detailed Solution:
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QUESTION 7:

Tool used in ultra-precision machining is

a) WC

b) HSS

c) Natural Diamond Tool

d) CBN

Correct Answer: (c)

Detailed Solution:
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QUESTION 8:

Which of the following is a high production rate process?

a) Mechanical micro machining

b) MEMS based processes

c) Ultra precision machining

d) Additive manufacturing processes

Correct answer: (b)

Detailed solution:
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QUESTION 9:

Which of the following path is a 3D machining or movement? (A – Starting point and D – Target

point)?

a) A—G—D

b) A—B—D

c) A—F—D

d) A—D

Correct answer: (d)

Detailed Solution: 3D machining follows the shortest possible path.

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QUESTION 10:

Machine tool feedback device gives information of

a) Position and velocity

b) Cutting temperature

c) Condition of cutting tool

d) Vibration

Correct answer: (a)

Detailed solution: Feedback gives information about position and velocity.

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 2
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Small things are less affected by

a) Mass

b) Inertia

c) Heat Storage

d) All of the above

e) Only (a) and (b)

f) Only (a) and (c)

Correct Answer: (d)

Detailed solution: Small things are more effected by surface area dependent phenomenon such as

contact forces or heat transfer and less effected by volume dependent phenomenon such as mass,

inertia or heat storage.

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QUESTION 2:

Surface tension is scaled with length at

a) l3

b) l2

c) l

d) l5

Correct answer: (c)

Detailed solution:
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QUESTION 3:

Which one of the following is scaled with length at l-1?

a) Area

b) Surface tension

c) Resistance

d) Moment of inertia

Correct answer: (c)

Detailed solution:

QUESTION 4:

When the radius of the pipe is scaled down proportionally,

a) Volumetric Flow and pressure drop per unit length both increase

b) Volumetric Flow decreases and pressure drop per unit length increases

c) Volumetric Flow and pressure drop per unit length both decrease

d) Volumetric Flow increases and pressure drop per unit length decreases

Correct Answer: (b)

Detailed Solution:

Q  ( a 4 P) / (8 L)

P  (8Vavg L) / a 2
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QUESTION 5:

Main driving factor in scaling law is

a) Weight to volume ratio

b) Surface area to volume ratio

c) Length to surface area ratio

d) Surface finish to tolerance ratio

Correct Answer: (b)

Detailed Solution: Main driver factor for scaling law is the surface area to the volume ratio.
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QUESTION 6:

What is less effective at small scale

a) Electrostatic forces

b) Surface tension

c) Inertial forces

d) All the above

e) Both (a) and (b)

f) Both (a) and (c)

Correct answer: (c)

Detailed Solution:
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QUESTION 7:

A square cantilever beam as shown in Figure below is scaled down proportionally (L and b) from 8

to 0.2. Maximum bending stress at the constraint

a) Decreases 40 times

b) Increases 40 times

c) Decreases 1600 times

d) Increases 1600 times

Correct Answer: (d)

Detailed Solution:
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QUESTION 8:

When the radius of the pipe is scaled down from 5 mm to 0.5 mm, rate of volumetric flow?

a) Decreases 10 times

b) Increases 10 times

c) Increases 10000 times

d) Decreases 10000 times

Correct answer: (d)

Detailed solution:
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QUESTION 9:

Small uncut chip thickness is responsible for

a) High Cutting Temperature

b) High Shear Yield Strength of workpiece

c) Low friction coefficient

d) All of the above

e) Only (a) and (c)

f) Only (b) and (c)

Correct answer: (b)

Detailed Solution:
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QUESTION 10:

Size effect has influence on

a) Chip Thickness

b) Chip formation

c) Cutting Force

d) All of the above

e) Only (a) and (c)

f) Only (b) and (c)

Correct answer: (d)

Detailed solution:

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 3
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

In micro machining, generally the ratio of uncut chip thickness to cutting edge radius is

a) Infinite

b) Less than or equal to 1

c) Very Large

d) Zero

Correct Answer: (b)

Detailed solution: hmin /r ≤ 1

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QUESTION 2:

Which of the following step of failure of ductile material is shown in below figure?

a) Inclusion

b) Void growth

c) Void Nucleation

d) Necking between voids

Correct answer: (d)

Detailed solution:
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QUESTION 3:

Which of the following material removal mechanism has significant effect on surface quality

deterioration?

a) Shearing

b) Ploughing

c) Rubbing

d) Extrusion

Correct answer: (c)

Detailed solution: Rubbing deteriorates the surface quality significantly.

QUESTION 4:

Which plane of Silicon is the strongest?

a) 100

b) 110

c) 101

d) 111

Correct Answer: (d)

Detailed Solution:
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QUESTION 5:

Which of the following is the unit of specific cutting energy?

a) J/mm3

b) J/mm2

c) N/mm

d) W/mm3

Correct Answer: (a)

Detailed Solution:

FcV F
u  c
bhcV bhc
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QUESTION 6:

Micro cutting of grains having different orientations would result in

a) High fluctuation of cutting force

b) Tool breakage

c) High surface roughness

d) All of the above

e) Only (a) and (b)

f) Only (a) and (c)

Correct answer: (d)

Detailed Solution:
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QUESTION 7:

What is minimum uncut chip thickness?

a) It is the minimum thickness of the uncut chip to avoid shearing of material during

machining

b) It is the minimum thickness of the uncut chip to reduce the tool wear

c) It is the minimum thickness of the uncut chip to reduce built-up edge formation

d) It is the minimum thickness of the uncut chip to remove material in the form of chip

Correct Answer: (d)

Detailed Solution: A minimum uncut chip thickness is always needed to maintain the chip from

uncut chip thickness and prevent ploughing and elastic recovery of material.

Refer lecture 13 at 17.00

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QUESTION 8:

Which one is the correct sequence of material removal mechanism with increase in the rake angle on

negative side?

a) Shearing  Extrusion  Ploughing  Rubbing

b) Shearing  Ploughing  Extrusion  Rubbing

c) Shearing  Rubbing  Ploughing  Extrusion

d) Extrusion  Shearing  Ploughing  Rubbing

Correct answer: (a)

Detailed solution: With increase in the negative rake angle material removal takes place in form of

shearing followed by extrusion, ploughing, and rubbing.

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QUESTION 9:

What is not correct with reference to anisotropic material?

a) Material properties are different in different planes

b) Material properties are different in crystal orientations

c) Force and energy required do not change when machining in different directions

d) Shear stress is different in different planes and directions.

Correct answer: (c)

Detailed Solution:
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QUESTION 10:

Match the following and choose correct option

A Shearing I Displacement of material by plastic upheaval

B Extrusion II Lowest rake angle on negative size

C Ploughing III Significant friction force

D Rubbing IV Similar to grinding

a) A-III, B-IV, C- I, D-II

b) A-IV, B-I, C- II, D-III

c) A-II, B-IV, C- I, D-III

d) A-II, B-I, C- IV, D-III

Correct answer: (c)

Detailed solution:

Shearing – Lowest rake angle on negative side

Extrusion- Similar to grinding in material removal mechanism

Ploughing- Displacement of material takes place by plastic upheaval

Rubbing- Significant friction force

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 4
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

What is the effect on cutting force in case of micro machining due to the reduction in uncut chip

thickness?

a) Increases proportionally

b) Decreases proportionally

c) Does not increase proportionally

d) Does not decrease proportionally

Correct Answer: (d)

Detailed solution:
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QUESTION 2:

Which of the following problem is unlikely to occur due to burr formation?

a) Improper part mating

b) Accelerated device wear

c) Decreased cost of production

d) Decreased device performance

Correct answer: (c)

Detailed solution:
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QUESTION 3:

Which of the following parameter is less responsible for burr formation?

a) Cutting Speed

b) Feed Rate

c) Temperature

d) Chip Thickness

Correct answer: (c)

Detailed solution:
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QUESTION 4:

Which of the following is a deburring process?

a) Ultrasonic wet peening

b) Electrochemical polishing

c) Both (a) and (b)

d) Cylindrical grinding

e) Both (b) and (d)

Correct Answer: (c)

Detailed Solution:
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QUESTION 5:

Which of the following is a short frequency component?

a) Waviness

b) Profile

c) Roughness

d) Lay

Correct answer: (c)

Detailed Solution:
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QUESTION 6:

Which of the following instrument can be used for the surface roughness measurement of the

complete region shown in below figure?

a) Atomic Force Microscope

b) Optical Microscope

c) Stylus Method

d) Both (a) and (b)

e) Both (a) and (c)

Correct Answer: (c)

Detailed Solution:
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QUESTION 7:

Which of the following is correct sequence of burr formation before crack propagation?

a) Continuous cutting Pre-Initiation Initiation Pivoting Burr Development

b) Pre-Initiation Initiation Continuous cutting  Pivoting Burr Development

c) Continuous cutting Pivoting Pre-Initiation Initiation Burr Development

d) Pivoting Continuous cutting  Pre-Initiation Initiation Burr Development

Correct answer: (a)

Detailed solution:
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QUESTION 8:

In the figure given below, size of the burrs will be more at the following location

a) 1

b) 2

c) 3

d) 4

Correct answer: (c)

Detailed Solution:
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QUESTION 9:

Which of the following type of burr is shown in below figure?

a) Tear Burr

b) Cut-off Burr

c) Rollover Burr

d) Poisson Burr

Correct answer: (a)

Detailed solution: Tear burr is the result of material tearing loose from the workpiece rather than
shearing clearly.
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QUESTION 10:

Select the correct sequence of processes with reference to increase in the specific cutting energy

a) Grinding  Micro machining  Conventional machining  Tensile testing

b) Tensile testing  Micro machining  Conventional machining  Grinding

c) Tensile testing  Conventional machining  Micro machining  Grinding

d) Grinding  Micro machining  Conventional machining  Tensile testing

Correct answer: (c)

Detailed solution:

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 5
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Elastic Recovery is dependent on

a) Size of cutting edge radius

b) Microstructure and hardness

c) Both (a) and (b)

d) Neither (a) nor (b)

Correct Answer: (c)

Detailed solution:
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QUESTION 2:

Which of the following is not correct about machining at micro scale?

a) High specific cutting energy

b) Difficulty in modeling

c) Tool breakage

d) Ease in sensing and monitoring

Correct answer: (d)

Detailed solution:
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QUESTION 3:

Which of the following is a moving body of a machine tool?

a) Machine Base

b) Column

c) Spindle box housing

d) Work tables

Correct answer: (d)

Detailed solution:
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QUESTION 4:

The major design issue in the context of the design of the machine as a system is

a) Structural Configuration

b) Structural Connectivity

c) Both (a) and (b)

d) Neither (a) nor (b)

Correct Answer: (d)

Detailed Solution:
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QUESTION 5:

The resolution of feedback encoder should be at least ______ than the machine controller?

a) 10 times lower

b) 10 times better

c) 100 times lower

d) 100 times better

Correct answer: (b)

Detailed Solution: Refer lecture 25 at 10.00.

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QUESTION 6:

Which of the following is correct about resolution?

a) If the system resolution is n, then all motions are integer multiples of n2

b) If the system resolution is n, then all motions are integer multiples of √𝑛

c) If the system resolution is n, then all motions are integer multiples of n

d) If the system resolution is n, then all motions are integer multiples of nn

Correct Answer: (c)

Detailed Solution:
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QUESTION 7:

A vacuum holder helps to,

a) Evacuate the microchips by sucking it away time to time

b) Hold the cutting fluid at the machining zone for a longer period

c) Handle the micro components without making any permanent deformations

d) Hold the tool monitoring systems at position for online monitoring

Correct answer: (c)

Detailed solution:
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QUESTION 8:

Which one of the below cannot be used to monitor the machining process in real time?

a) Dynamometer

b) Touch probe

c) Acoustic emission sensor

d) Accelerometer

Correct answer: (b)

Detailed Solution:
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QUESTION 9:

Bidirectional repeatability is difficult to achieve in axis movement due to

a) Hysteresis of mechanical movement

b) Linear movement of drive

c) Low accuracy of the slide movement

d) Low resolution of the slide movement

Correct answer: (a)

Detailed solution:
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QUESTION 10:

What is resolution with reference to terms of machine tool?

a) The least variation in the dimensions of the machined component and the desired value.

b) How fast the tool or workpiece can reach to the desired location during command execution.

c) The least increment of movement, the machine is capable to produce.

d) It is related to the tolerance of the machined component.

Correct answer: (c)

Detailed solution:

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 6
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Which of the following is correct about closed loop structure?

a) Good thermal stability

b) Easy access to work zone

c) Strong ridged structural loop

d) All of the above

e) Only (a) and (b)

f) Only (a) and (c)

Correct Answer: (d)

Detailed solution:
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QUESTION 2:

CMM stands for

a) Co-ordinate Machine Measurement

b) Centre Measuring Machine

c) Co-ordinate Measuring Machine

d) Centre Machine Measurement

Correct answer: (c)

Detailed solution: CMM stands for Coordinate measuring machine.

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QUESTION 3:

Which of the following is correct match of the numbers marked on the figure given below?

a) 1-Leading Edge 2-Stagnant Edge 3-Bleeding Edge

b) 1- Stagnant Edge 2- Leading Edge 3-Bleeding Edge

c) 1-Leading Edge 2- Bleeding Edge 3- Stagnant Edge

d) 1- Bleeding Edge 2- Leading Edge 3- Stagnant Edge

Correct answer: (b)

Detailed solution:
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QUESTION 4:

The sensitive directions in case of Milling Machine are

a) X-axis and Y-axis

b) X-axis and Z-axis

c) Y-axis and Z-axis

d) X-axis, Y-axis and Z-axis

Correct Answer: (d)

Detailed Solution:
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QUESTION 5:

What are the different components of error in a linear movement?

a) 1 position error, 2 straightness error, 2 roll error and 1 tilt error

b) 1 position error, 2 straightness error, 1 roll error and 2 tilt error

c) 2 position error, 1 straightness error, 2 roll error and 1 tilt error

d) 2 position error, 1 straightness error, 1 roll error and 2 tilt error

Correct answer: (b)

Detailed Solution:
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QUESTION 6:

The degree of freedom for bolt and nut combination is

a) Translation and Rotation (Independent)

b) Only translation

c) Only rotation

d) Translation and Rotation (Coupled)

Correct Answer: (d)

Detailed Solution:
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QUESTION 7:

When travelling in X- direction, Flatness can be defined as

a) Displacement error along the X-axis

b) Displacement error along the Y-axis

c) Displacement error along the Z-axis

d) Both (a) and (b)

e) Both (a) and (c)

Correct answer: (c)

Detailed solution:
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QUESTION 8:

Kinematic errors are not related to

a) Imperfect Geometry

b) Alignment and dimension of the machine tools

c) Wear or material aging

d) Range of the spindle speed

Correct answer: (d)

Detailed Solution:
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QUESTION 9:

When travelling in X- direction, Straightness can be defined as

a) Displacement error along the X-axis

b) Displacement error along the Y-axis

c) Displacement error along the Z-axis

d) Both (a) and (b)

e) Both (a) and (c)

Correct answer: (b)

Detailed solution:
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QUESTION 10:

Drift error in the machine tool is due to

a) Aging of the components

b) Improper mating of the components

c) Thermal expansion of the components

d) Failure of the components

Correct answer: (a)

Detailed solution:

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 7
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Which of the following is a preferable material for making structure of micro machine tool?

(a) Metal

(b) Granite

(c) Ceramic

(d) Polymer concrete

Correct Answer: (d)

Detailed solution:
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QUESTION 2:

Which of the following is the least important material property of the machine frame?

(a) Young’s modulus

(b) Shear modulus

(c) Poisson’s ratio

(d) Thermal conductivity

Correct answer: (c)

Detailed solution:
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QUESTION 3:

Increasing order of Young’s modulus of different material which are used for making machine

structure is:

(a) Elastomers<Non-technical ceramics<Technical ceramics< Polymers

(b) Elastomers<Technical ceramics<Non-technical ceramics< Polymers

(c) Elastomers<Polymers<Composite<Technical ceramics

(d) Elastomers< Polymers < Technical ceramics< Non-technical ceramics

Correct answer: (c)

Detailed solution: Young’s modulus of technical ceramics is maximum.

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QUESTION 4:

Specific energy requirement for making the high strength material will be

(a) Low

(b) High

(c) In between low and high

(d) Specific energy requirement is not the criteria for making high strength material

Correct Answer: (b)

Detailed Solution:
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QUESTION 5:

What you will do to reduce the local strain in the component?

(a) Reduce thickness of the wall

(b) Increase thickness of the wall

(c) Reduce the weight of the component

(d) Increase the weight of the component

Correct answer: (b)

Detailed Solution:
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QUESTION 6:

Which one of the following statement is true?

(a) Polymer concrete is heavier than C.I.

(b) C.I. has better thermal stability than Polymer concrete

(c) Polymer concrete has superior dynamic and static rigidity

(d) C.I. has better damping capacity than Polymer concrete

Correct Answer: (c)

Detailed Solution:
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QUESTION 7:

Axis of the guideways should have

(a) Low velocity as well as stiff bearing

(b) High velocity as well as stiff bearing

(c) High acceleration as well as stiff bearing

(d) Low acceleration as well as stiff bearing

Correct answer: (c)

Detailed solution:
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QUESTION 8:

What is the drawback of the granite when it is used for making machine tool?

(a) Low damping

(b) Low wear resistance

(c) Moisture absorbing capacity

(d) Presence of residual stress

Correct answer: (c)

Detailed Solution:
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QUESTION 9:

Which one of the following guideways is more preferable for taking load in up-down as well as left-

right directions?

(a) Hydrostatic

(b) Hydrodynamics

(c) Linear

(d) Box

Correct answer: (c)

Detailed solution:
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QUESTION 10:

Basic static load rating of the roller is roughly defined as:

(a) Total permanent deformation is the half of the diameter of the roller

(b) Total permanent deformation is 1/1000 of the diameter of the roller

(c) Total permanent deformation is 1/10000 of the diameter of the roller

(d) Total permanent deformation is 1/100000 of the diameter of the roller

Correct answer: (c)

Detailed solution:

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 8
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

The function of precision laser system in MMC is to determine

(a) Only diameter of the tool

(b) Only length of the tool

(c) Both diameter and length of the tool

(d) Rake and clearance angle of the tool

Correct Answer: (c)

Detailed solution: Precision laser system is used to determine the diameter and length of the tool.
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QUESTION 2:

Which one of the following factors affect air bearing life the most?

(a) Speed of rotation

(b) External load

(c) Acceleration

(d) Cleanliness of air

Correct answer: (d)

Detailed solution: Speed of rotation, external load, and acceleration don’t have any influence on air

bearing life. Cleanliness of the air has the greatest impact on the life of the bearing.
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QUESTION 3:

Mode of failure of air bearing

(a) Spalling wear

(b) Smearing wear

(c) Erosion wear

(d) Fretting wear

Correct answer: (c)

Detailed solution:
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QUESTION 4:

The variation of radial stiffness of air bearing with respect to shaft angular position is

(a) Non uniform

(b) Uniform

(c) Triangular

(d) Trapezium

Correct Answer: (b)

Detailed Solution:
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QUESTION 5:

Which of the following bearing offers the highest friction & has the lowest cost?

(a) Air bearing

(b) Hydrostatic bearing

(c) Roller bearing

(d) Cylindrical bearing

Correct answer: (c)

Detailed Solution:
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QUESTION 6:

On which part of the linear motor magnet is present?

(a) Rotor

(b) Stator

(c) Forcer

(d) Coil

Correct Answer: (b)

Detailed Solution:
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QUESTION 7:

The maximum speed of a linear motor is governed by

(a) Bus voltage

(b) Speed of the control electronics

(c) Resolution

(d) All of the above

(e) Only (a) and (c)

(f) Only (b) and (c)

Correct answer: (d)

Detailed solution:
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QUESTION 8:

The stiffness of the linear motor does not depend upon

(a) Peak force of the motor

(b) Resolution of the feedback

(c) Current available

(d) Speed of the travel

Correct answer: (d)

Detailed Solution:
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QUESTION 9:

The problem of heating in the linear drive is due to

(a) Thermal heating

(b) Mechanical friction

(c) Both of the above

(d) Electrical power supply

Correct answer: (d)

Detailed solution: With the increase in the current temperature rise due to I2R losses; as a result,

heating will increase.

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QUESTION 10:

Which statement is/are true for MMC (Micro Machining Center)?

(a) It has high moisture retention capacity and low damping coefficient

(b) It has high moisture retention capacity and high damping coefficient

(c) It has low moisture retention capacity and low damping coefficient

(d) It has low moisture retention capacity and high damping coefficient

Correct answer: (d)

Detailed solution: As machine base is made of polymer concrete it provide high damping coefficient
and low moisture retention capacity.

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 9
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

What is 4 in 4 Bit encoder?

(a) It has 4 LEDs

(b) It has 4 transmitters

(c) Both (a) and (b)

(d) It has 4 tracks

Correct Answer: (d)

Detailed solution:
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QUESTION 2:

Which of the following components or mechanisms is not the part of the belt driven spindle?

(a) Tooling system

(b) Drawbar mechanism

(c) Tool release system

(d) linear encoder

Correct answer: (d)

Detailed solution:
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QUESTION 3:

Spindle bearing should not provide

(a) High rotational speed

(b) Low transfer torque

(c) High power to the cutting tool

(d) Reasonable loading

Correct answer: (b)

Detailed solution:
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QUESTION 4:

Which of the following statement(s) is/are true?

(a) Angular contact bearing provide precision

(b) Tapered bearing is used for high load application

(c) Both (a) and (b)

(d) Tapered bearing has lower stiffness over ball bearings

Correct Answer: (c)

Detailed Solution:
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QUESTION 5:

Which of the following bearing is highly accurate and used in high speed spindle?

(a) ABEC 1

(b) ABEC 5

(c) ABEC 7

(d) ABEC 9

Correct answer: (d)

Detailed Solution:
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QUESTION 6:

Which of the following statement(s) is/are true?

(a) To have greater radial load carrying capacity bearing should have high contact angle

(b) To have greater radial load carrying capacity bearing should have low contact angle

(c) To have greater bending load carrying capacity bearing should have high contact angle

(d) To have greater axial load carrying capacity bearing should have low contact angle

Correct Answer: (b)

Detailed Solution:
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QUESTION 7:

Which of the following statement(s) is/are true?

(a) Low contact angle of a spindle is primarily used in drilling

(b) Low contact angle of a spindle is primarily used in milling

(c) High contact angle of a spindle is primarily used in shaping

(d) High contact angle of a spindle is primarily used in planning

Correct answer: (b)

Detailed solution:
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QUESTION 8:

What is the importance of the bearing preloading?

(a) To provide excess play by applying axial or thrust forces to a bearing

(b) To remove excess play by applying more friction to a bearing

(c) To provide excess play by applying radial and thrust forces to a bearing

(d) To remove excess play by applying axial or thrust forces to a bearing

Correct answer: (d)

Detailed Solution:
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QUESTION 9:

Excessive preloading of the bearing doesn’t result in

(a) Increased heat generation

(b) Excessive stress

(c) Higher chances of fatigue

(d) Decreased torque

Correct answer: (d)

Detailed solution:
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QUESTION 10:

What is the purpose(s) of duplex bearing?

(a) To provide high rotational speed

(b) To provide high feed rate during machining

(c) To provide less friction

(d) To provide load sharing and high stiffness

Correct answer: (d)

Detailed solution:

***********END**********
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Introduction to Mechanical Micro Machining

Assignment- Week 10
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

In hybrid ceramic bearing, inner and outer races are made up of __

a) Ceramic
b) Steel
c) Tungsten carbide
d) Aluminum

Correct Answer: (b)

Detailed Solution:
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QUESTION 2:

Which of the following statement/s is/are true in the context of bearings?

a) Aerostatic bearing operates at a lower speed as compared to the hybrid ceramic bearing
b) Hybrid ceramic bearing operates at a lower speed as compared to the aerostatic bearing
c) Torque required by hybrid ceramic bearing is less as compared to aerostatic bearing
d) Both (a) and (c)
e) Both (b) and (c)

Correct Answer: (b)

Detailed Solution:
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QUESTION 3:

What is the cause of aerostatic spindle warpage?

a) It is due to differential expansion at certain locations on the spindle due to hot air impinging
b) It is due to differential contraction at certain locations on the spindle due to cold air impinging
c) It is due to differential expansion at certain locations on the spindle due to mist air impinging
d) It is due to differential contraction at certain locations on the spindle due to cold water impinging

Correct Answer: (b)

Detailed Solution:
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QUESTION 4:

In high speed micromachining, bell mouthing is a problem which appears due to the
a) Expansion of spindle shaft
b) Slippage of tool holder
c) Vibration of the machine tool
d) Bending of the micro tool

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 48, Time: 8:00)

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QUESTION 5:

Which tool retention system is preferable for high speed spindle used in high precision machining
centers?

a) BT
b) CAT
c) ISO
d) HSK

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 48, Time: 11:00)

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QUESTION 6:

The required properties of a micro cutting tool is/are

a) High coefficient of friction
b) More number of cutting edges
c) Desired flank geometry
d) Both (a) and (b)
e) Both (a) and (c)

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 49, Time: 13:33)

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QUESTION 7:

What is the full form of WEDG (a well-known micro tool fabrication process)?
a) Wear electric diamond grinding
b) Water electric discharge grinding
c) Wire electric discharge grinding
d) Wire electric diamond grinding

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 50, Time: 3:03)

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QUESTION 8:

Removal of the material and re-sharpening of the grinding wheel both occurs simultaneously in
a) Micro-grinding
b) Wire electric discharge grinding
c) Electrolytic in-process dressing (ELID)
d) Piezoelectric or Nano-grinding

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 51, Time: 2:49)

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QUESTION 9:

The micro-tool with dull cutting edges likely to be broken because

a) Stress increases beyond the permissible limit.

b) Material cannot be removed.
c) The tool becomes mechanically weak.
d) None of the above

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 51, Time: 11:51)

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QUESTION 10:

In electro discharge machining (EDM), the material is removed by

a) Formation of chips
b) Melting
c) Melting and vaporizing
d) All of the above

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 52, Time: 3:25)

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 11
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

Bending of the micro tools becomes prominent when

a) Both spindle speed and feed rate are high

b) Both spindle speed and feed rate are low

c) Spindle speed low but feed rate high

d) Spindle speed high but feed rate low

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 53, Time: 3:03)

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QUESTION 2:

Which one is not the key issue for the breakage of micro tools?

a) Higher cutting forces relative to size

b) Chip clogging
c) Formation of built-up edge (BUE)
d) High temperature

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 53, Time: 3:25)

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QUESTION 3:

What are the limitations to make a small–scale micro machine tools

a) Lack of rigidity
b) Base vibration
c) Machining difficulties
d) Both (a) and (b)
e) Both (a) and (c)
f) Both (b) and (c)

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 54, Time: 5:01)

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QUESTION 4:

Advantages expected from micro factories are

a) Capital investment is reduced

b) High speed machining is possible
c) Proper utilization of the space
d) Both (a) and (b)
e) Both (a) and (c)
f) Both (b) and (c)

Correct Answer: (e)

Detailed Solution:

(Refer: Lecture 54, Time: 7:44)

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QUESTION 5:

Advantages expected from micro factories in terms of technical aspect is/are

a) Freedom of configuration
b) Low resonant frequency
c) Shortened ramp-up
d) Only (a) and (b)
e) Only (a) and (c)

Correct Answer: (e)

Detailed Solution:

(Refer: Lecture 55, Time: 4:07)

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QUESTION 6:

The advantages of micro factories in terms of environmental aspects is /are

a) No coolant or lubrication required

b) Only a few operators required
c) Easy control of waste and pollution
d) All of the above

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 55, Time: 6:41)

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QUESTION 7:

The suitable tool material for ultra-precision machining is

a) HSS
b) Coated tungsten carbide
c) Natural diamond
d) CBN

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 56, Time: 6:21)

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QUESTION 8:

The most useful process for the fabrication of astronomical telescope mirrors is
a) Diamond turning
b) CNC machining
c) Grinding
d) Honing

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 56, Time: 8:09)

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QUESTION 9:

In X-Z axis diamond turning machine, the tool slide along

a) X axis

b) Y axis

c) Z axis

d) None of the above

Correct Answer: (c)

Detailed Solution:

(Refer: Lecture 57, Time: 2:00)

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QUESTION 10:

The preferable configuration to generate concave surface in DTM is

a) X-Z configuration

b) R- ϴ configuration

c) X-T configuration

d) All of the above

Correct Answer: (b)

Detailed Solution:

(Refer: Lecture 57, Time: 8:15)

***********END***********
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Introduction to Mechanical Micro Machining

Assignment- Week 12
TYPE OF QUESTION: MCQ/MSQ
Number of questions: 10 Total mark: 10 X 1 = 10

QUESTION 1:

The material removal rate (MRR in mm3/min) of turning process can be expressed as
a) Depth of cut × feed × cutting velocity
b) Depth of cut × feed
c) Feed × cutting velocity
d) None of the above

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 58, Time: 2:08)

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QUESTION 2:

Important parameters for average material removal rate of lapping process (i.e., soft –loop finishing
technique) are
a) Depth of cut, feed, cutting velocity
b) Depth of cut and feed
c) Feed and cutting velocity
d) Pressure and velocity

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 58, Time: 4:02)

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QUESTION 3:

When the uncut chip thickness is more than 10 µm then

a) Grain boundaries become the origin of breakage
b) Dislocation become origin of breakage
c) Point defects spaced between 1-100 nm become the origin of breakage
d) None of the above

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 58, Time: 7:41)

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QUESTION 4:

In diamond turning, the cutting tool with smaller nose radius is suitable
a) To make smaller features
b) To machine fragile job
c) To make external features
d) Both (a) and (b)
e) Both (a) and (c)

Correct Answer: (d)

Detailed Solution:

(Refer: Lecture 59, Time: 1:04)

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QUESTION 5:

Peak-to-valley height (h) of the diamond turned surface can be calculated as (where f is feed per
revolution and R is nose radius)
a) f2/8R
b) f2/2R
c) f2/6R
d) f2/R

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 59, Time: 2:03)

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QUESTION 6:

Basic compositions of sensing system are

a) Sensor, Transform or conversion, Signal processing, and Decision making

b) Sensor, Signal processing, Machine, and Decision making

c) Machine, Transform or conversion, and Signal processing

d) Machine, Operator, Decision making and Sensor

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 60, Time: 11:41)

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QUESTION 7:

Real time monitoring of the machining operation falls under

a) Continuous measurement system
b) Intermittent measurement system
c) Multiple measurement system
d) Coherence measurement system

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 61, Time: 1:25)

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QUESTION 8:

Cutting forces are usually measured by

a) Pyrometer
b) Dynamometer
c) High speed camera
d) Accelerometer

Correct Answer: (b)

Detailed Solution:

(Refer: Lecture 61, Time: 11:20)

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QUESTION 9:

Acoustic emission can monitor the

a) Deformation at submicron scale with high level of precision

b) Deformation at millimeter scale with high level of precision

c) Deformation at submicron scale with low level of precision

d) Deformation at millimeter scale with low level of precision

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 62, Time: 2:37)

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QUESTION 10:

Sources of acoustic emission (AE) in machining is/are

a) Elastic recovery of material
b) Material softening
c) Both (a) and (b)
d) Neither (a) nor (b)

Correct Answer: (a)

Detailed Solution:

(Refer: Lecture 62, Time: 3:46)

***********END***********