Basic Of Unconventional Machining | interview Question and Answers

1. What is the need for unconventional machining processes?
High production rate
Low cost of production
Better surface integrity,
High surface finish

2. What are the characteristics of UCM processes?

Performance is independent of strength barrier
Use different kinds of energy in direct form
In general, low MRR but better quality products
Comparatively high initial investment cost

3.Differentiate the conventional and unconventional machining processes in terms of principles.

In conventional processes, the material is removed in the form of chips by the advancing cutting tool that plastically deforms (shearing) the material ahead. In the case of the UCM processes, energy (Electrical, Chemical, Thermo-Electric, Mechanical) in its direct form is utilized for the material removal and so there is no physical contact between the workpiece and tool.

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4. What are the various types of energy sources used in non-traditional machining techniques? Give examples for each.

Pneumatic pressure- AJM
Hydraulic pressure- WJM, USM, AWJM
Corrosion- CHM, CHB, PCM
High current density in electrolytes- ECM
High voltage- EDM (for sparking); IBM, EBM (ionizing); LBM
(creating avalanche in lazing medium);
PAM (for ionizing the plasma gases)

5. Classify the different types of unconventional machining processes based on the mechanical energy.

Abrasive Jet Machining (AJM)
Water Jet Machining (WJM)
Ultrasonic Machining (USM)
Abrasive Water Jet Machining (AWJM)

6. Identify the mechanism of material removal, transfer media and energy source for EDM.

Mechanism of material removal- Fusion of materials by arcs
Transfer media – Electron stream
Energy source – High voltage

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7. Identify the mechanism of material removal, transfer media and energy source for ECM.

Mechanism of material removal- Ion displacement
Transfer media – Electrolyte
Energy source – High current

8. Identify the mechanism of material removal, transfer media and energy source for EBM.

Mechanism of material removal- Vaporization
Transfer media – Electron stream
Energy source – High voltage

9. Identify the mechanism of material removal, transfer media and energy source for LBM.

Mechanism of material removal- Vaporization
Transfer media – Amplified coherent light radiation
Energy source – High voltage

10. Identify the mechanism of material removal, transfer media and energy source for PAM.

Mechanism of material removal- Vaporization
Transfer media – Ionised gas stream
Energy source – High voltage

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11. Identify the mechanism of material removal, transfer media and energy source for USM.

Mechanism of material removal- Erosion
Transfer media – High velocity particles
Energy source – Hydraulic pressure

12. Identify the mechanism of material removal, transfer media and energy source for AJM.

Mechanism of material removal- Erosion
Transfer media – High velocity particles
Energy source – Pneumatic pressure

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13. Identify the mechanism of material removal, transfer media and energy source for WJM.

Mechanism of material removal- Erosion
Transfer media – High velocity water jet
Energy source – Hydraulic pressure

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