Here are 1000 Manufacturing Processes MCQ (Chapterwise).
1. Which of the following two disciplines are tied by a common database?
a) CAD and CAM
b) drafting and documentation
c) documentation and geometric modeling
d) none of the mentioned
View Answer
Explanation: Because of their joint benefits, computer-aided design and computer-aided manufacturing are often combined into CAD/ CAM systems. This combination allows the transfer of information from the design stage to the stage of planning for manufacture, without the need to reenter the data on part geometry manually.
2. Which of the following software is used to provide the users with various functions to perform geometric modeling and construction?
a) graphics software
b) programming software
c) operating software
d) application software
View Answer
Explanation: Operating software is used to control the computer’s work flow, organize its data and perform house keeping functions.
Graphics software is used to provide users with various functions to perform geometric modelling and construction.
Application software performs the data entry, design, analysis, drafting and manufacturing functions.
Programming software enables the to implement custom application or modify the system for specialized needs.
3. What is the relationship between CAD/CAM?
a) manufacturing and marketing
b) science and engineering
c) design and marketing
d) design and manufacturing
View Answer
Explanation: None
4. Which of the following device is mostly associated with automation?
a) NC machine
b) flexible manufacturing
c) computer graphics workstation
d) robots
View Answer
Explanation: Only robots are associated with automation.
5. Which of the following software performs the data entry, design, analysis, drafting, and manufacturing functions?
a) graphics software
b) programming software
c) operating software
d) application software
View Answer
Explanation: Operating software is used to control the computer’s work flow, organize its data and perform house keeping functions.
Graphics software is used to provide users with various functions to perform geometric modelling and construction.
Application software performs the data entry, design, analysis, drafting and manufacturing functions.
Programming software enables the to implement custom application or modify the system for specialized needs.
6. Which of the following software enables to implement custom applications or modify the system for specialized needs?
a) graphics software
b) programming software
c) operating software
d) application software
View Answer
Explanation: Operating software is used to control the computer’s work flow, organize its data and perform house keeping functions.
Graphics software is used to provide users with various functions to perform geometric modelling and construction.
Application software performs the data entry, design, analysis, drafting and manufacturing functions.
Programming software enables the to implement custom application or modify the system for specialized needs.
7. On which of the following just in time manufacturing philosophy emphasizes?
a) man power
b) profit
c) inventory
d) manufacturing
View Answer
Explanation: None.
8. Why designs are periodically modified?
a) to strive for zero-based rejection and waste
b) to make products easier and faster to manufacture
c) to improve product performance
d) all of the mentioned
View Answer
Explanation: Designs are periodically modified to
i) Consider new materials and processes that are continually being developed
ii) Strive for zero-based rejection and waste
iii) Improve product performance
iv) Make products easier and faster to manufacture
9. Why sustainable manufacturing is required?
a) proper maintenance
b) reuse
c) conserving resources
d) all of the mentioned
View Answer
Explanation: The concept of sustainable manufacturing emphasizes the need for conserving resources, particularly through proper maintenance and reuse.
10. Which of the following are the chemical properties of good product material?
a) corrosion
b) surface treatment
c) oxidation
d) all of the mentioned
View Answer
Explanation: Chemical properties of primary concern in manufacturing are susceptibility to oxidation and corrosion and to the various surface-treatment processes.
11. Which of the following operation is used to make a ball bearing?
a) Upsetting
b) Press forging
c) Roll forging
d) Skew rolling
View Answer
Explanation: A special type, skew rolling is used to manufacture milling steel ball, bearing ball blanks.
12. Which of the following software is used to control the computer’s work flow, organize its data and perform house keeping functions?
a) graphics software
b) programming software
c) operating software
d) application software
View Answer
Explanation: Operating software is used to control the computer’s work flow, organize its data and perform house keeping functions.
Graphics software is used to provide users with various functions to perform geometric modelling and construction.
Application software performs the data entry, design, analysis, drafting and manufacturing functions.
Programming software enables the to implement custom application or modify the system for specialized needs.
13. Which of the following are cleaning fluids?
a) emulsions
b) solvents
c) alkaline solutions
d) all of the mentioned
View Answer
Explanation: Common cleaning fluids used in conjunction with electrochemical processes for more effective cleaning include the following:
a) Alkaline solutions: A complex combination of water-soluble chemicals, alkaline solutions are the least expensive and most widely used cleaning fluids in manufacturing operations. Small parts may be cleaned in rotating drums or barrels. Most parts are cleaned on continuous conveyors by spraying them with the solution and rinsing them with water.
b) Emulsions: Emulsions generally consist of kerosene and oil-in-water and various types of emulsifiers.
c) Solvents: Typically petroleum solvents, chlorinated hydrocarbons, and mineral spirits, solvents generally are used for short runs. Fire and toxicity are major hazards.
d) Hot vapors: Chlorinated solvents can be used to remove oil, grease, and wax. The solvent is boiled in a container and then condensed. This hot-vapor process is simple, and the cleaned parts are dry.
e) Acids, salts, and mixtures of organic compounds: These are effective in cleaning parts covered with heavy paste or oily deposits and rust.
14. Which of the following forging operation is Heading?
a) Embossing
b) Coining
c) Piercing
d) Upsetting
View Answer
Explanation: A heading tool or ram is positioned perpendicular to the cross sectioned end face of a rod or bar gripped in a die. On application of pressure, the length of the rod is reduced, and the diameter is increased (upset). This manufacturing process used extensively in the production of fasteners, to form bolt heads, screw heads etc.
15. Which of the following casting technique has a greater impact in semiconductor industry?
a) single crystal
b) induction melting
c) directional solidification
d) conventional casting
View Answer
Explanation: Single-crystal growing is a major activity in the semiconductor industry in the manufacture of the silicon wafers in microelectronic devices.
16. In which of the following casting process the sand is mixed with a thermosetting resin to form a mould?
a) Shell moulding
b) Squeeze casting
c) Centrifugal casting
d) Die casting
View Answer
Explanation: The first step in the shell mold casting process is to manufacture the shell mold. The sand we use for the shell molding process is of a much smaller grain size than the typical greensand mold. This fine-grained sand is mixed with a thermosetting resin binder.
17. Which of the following is used to form Complex shapes effectively?
a) Metal casting
b) Sand casting
c) Powder metallurgy
d) Turning
View Answer
Explanation: Powder metallurgy allows us to create high-quality components, while near-net-shape dimensional control provides a high degree of control over the manufacturing process, facilitating the production of complex shapes.
18. For manufacturing of a certain amount of hole, maximum hole size was found to be 50.14 mm and minimum hole size was found to be 49.98. What will be the Tolerance in mm?
a) 0.14
b) 0.15
c) 0.16
d) 0.17
View Answer
Explanation: Tolerance is the maximum deviation in size of shaft or hole.
19. In the manufacturing of hole and shaft, the maximum shaft diameter was 49.88 mm and the minimum hole diameter was found to be 49.94 mm. Which of the following is correct?
a) Interference fit
b) Transition fit
c) Clearance fit
d) None of the mentioned
View Answer
Explanation: When size of smallest hole is more than size of biggest shaft then it is clearance fit.
20. For helical gears, the angle between hob’s spindle axis and workpiece’s spindle axis must be _____ as the helix angle of the helical gear.
a) decreased by the half amount
b) increased by the half amount
c) decreased by the same amount
d) increased by the same amount
View Answer
Explanation: For manufacturing the helical gear, one has to consider helix angle of the gear. While hobbing the helical gear, angle between hob spindle axis and workpiece spindle axis should be increased by an angle equal to helix angle of the gear.
21. What causes an un-proportionally thin and high tooth in the toe region, and a short and thick tooth at the heel?
a) Difference in feed rates
b) Difference in PCDs of the generating gears
c) Error in indexing while manufacturing
d) Difference in outer and inner circumference of the generating gear
View Answer
Explanation: The difference in outer and inner circumference of the generating gear causes an extreme tooth thickness taper that leads to uneven tooth profile.
22. Which of the following is the most common material used to produce forming rolls?
a) Chrome steels
b) Oil hardened tool steels
c) Aluminium
d) Carbide
View Answer
Explanation: Several types of materials are used in the manufacture of the forming rolls and oil hardened tool steel being the most common. For extended tool life, hardened high-carbon, high-chromium too steels are used. On extremely tough forming applications involving high temperatures and or abrasive materials, aluminium/bronze or carbide rolls are required.
23. Which of the following is correct about ECG?
a) Burr-free sharpening of needles
b) Machining of soft metals like aluminium can be easily done
c) Lower MRRs when grinding hard, heat-sensitive materials
d) Difficult to machine materials with high hardness like tungsten carbide
View Answer
Explanation: Applications of ECG are as follows;
(1) Single largest use for ECG is in the manufacturing and remanufacturing of turbine blades and vanes for aircraft turbine engines
(2) Grinding of tungsten carbide tool inserts
(3) Re-profiling worn locomotive traction motor gears
(4) Burr-free sharpening of hypodermic needles
(5) Grinding of surgical needles, other thin wall tubes, and fragile parts
(6) Machining of fragile or very hard and tough material – honey comb, thin walled tubes and skins
(7) High MRR’s when grinding hard, tough, stringy, work-hardenable or heat sensitive materials.
24. Which of the following manufacturing process is favourable for making tool for ECM?
a) Cold forging
b) Casting
c) Shaping
d) Laser cutting
View Answer
Explanation: Shaping the tool is usually not a problem since all the materials are easy to machine. Cold forging and electroforming are favourable methods of tool making.
25. According to which of the following Porous materials are classified?
a) total area
b) pore size
c) manufacturing method
d) difference between initial and final mass
View Answer
Explanation: Following the International Union of Pure and Applied Chemistry (IUPAC) nomenclature used to classify porous materials as a function of their pore size (dp).
26. Why do the pore characteristics of the resulting pSi structures depend upon the doping type? Choose the most correct option.
a) The pore formation mechanism relies on doping
b) Atomic size of doping atom affects the final structure
c) Processing time depends on the doping
d) The manufacturing process is selected on the basis of doping
View Answer
Explanation: The reason why the pore characteristics of the resulting pSi structures depend upon the doping type and its level of the silicon wafer is that the pore formation mechanism relies on these parameters.
27. Which of the following is the odd-one out?
a) micro-grinding
b) micro-turning
c) micro-milling
d) micro-EBM
View Answer
Explanation: Micro-turning, micro-milling and micro-grinding are traditional material removal processes; whereas, micro-EBM (micro electron beam machining) process is one of the advanced manufacturing processes.
28. Thermal micromachining processes can be used to produce reduced hole diameter, lower hole pitch.
a) False
b) True
View Answer
Explanation: Reduced hole diameter, lower hole pitch and longer head can be manufactured by thermal micromachining processes. These processes are used to manufacture computer hard disc drive heads, inkjet printer heads, sensors, infrared images.
29. Manufacturing of capillary electrophoresis chips has an application of which of the following process?
a) Electron beam machining
b) Abrasive jet machining
c) Chemical Milling
d) Ultrasonic machining
View Answer
Explanation: The device consists of a glass chip that contains a single separation channel as well as an integrated conductivity detection cell. In contrast to most micro-fluidic glass devices, the channels are not wet etched in HF but machined by AJMM which allows the creation of micro-structures below 100μm, and additionally makes parallel holes machining at very low costs outside the clean room environment.
30. WEDM process can be used for the manufacturing micro-tools.
a) False
b) True
View Answer
Explanation: Following are the few areas where the WEDM process is used:
• Cutting of Gears, Strippers, Punches, and Dies
• Manufacturing hard Electrodes
• Manufacturing micro-tooling for Micro-EDM, Micro-USM and such other micromachining applications.
Chapterwise Multiple Choice Questions on Steam and Gas Turbines
- Crystallography and Defects in Solid
- Mechanical Properties and Testing and Phase Diagram
- Ferrous Metal, Non-Ferrous Metal and Heat Treatment
- Magnetic Properties of Material, Electrical Properties of Materials, Plastics, Ceramics and Composites
- Metal Cutting
- Cutting-Tool Materials and Cutting Fluids
- Lathe Machines, Shaping and Slotting
- Milling, Drilling and Reaming
- Grinding, Surface Finishing Operations and Unconventional Machining Processes
- Metrology, Welding, Fusion-Welding Processes and Unconventional Welding Methods
- Powder Metallurgy, NC Part Programming and Metal Casting and Gating Systems
- Forming, Metal Forming Processes and Heat Transfer
- Jigs and Fixture, Applications and Gears
1. Manufacturing Processes MCQ on Crystallography and Defects in Solid
The section contains manufacturing processes multiple choice questions and answers on concepts of crystallography, miller indices and defects and imperfections in solids.
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2. Manufacturing Processes Multiple Choice Questions on Mechanical Properties and Testing and Phase Diagram
The section contains manufacturing processes questions and answers on mechanical properties and testing, non destructive testing, phase diagrams and iron carbon phase diagrams.
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3. Manufacturing Processes MCQ on Ferrous Metal, Non-Ferrous Metal and Heat Treatment
The section contains manufacturing processes MCQs on ferrous and non ferrous metals and heat treatment methodologies.
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4. Manufacturing Processes Multiple Choice Questions on Magnetic Properties of Material, Electrical Properties of Materials, Plastics, Ceramics and Composites
The section contains manufacturing processes multiple choice questions and answers on magnetic and electric properties of materials, basics of plastics, ceramics basics and composites basics.
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5. Manufacturing Processes MCQ on Metal Cutting
The section contains manufacturing processes questions and answers on tool geometry and its nomenclature, chips theory, tool wear and its failure, cutting tool materials and fluids, tool temperature and cutting mechanics.
6. Manufacturing Processes Multiple Choice Questions on Cutting-Tool Materials and Cutting Fluids
The section contains manufacturing processes MCQs on cutting mechanics and forces power, cutting tool materials, machinability, cutting fluids and turning process.
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7. Manufacturing Processes MCQ on Lathe Machines, Shaping and Slotting
The section contains manufacturing processes multiple choice questions and answers on various concepts which include lathe basics, capstan and turret lathe, shaper parts and mechanism and slotters.
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8. Manufacturing Processes Multiple Choice Questions on Milling, Drilling and Reaming
The section contains manufacturing processes questions and answers on milling basics, milling cutters, indexing, attachments and operation and twist drill geometry.
9. Manufacturing Processes MCQ on Grinding, Surface Finishing Operations and Unconventional Machining Processes
The section contains manufacturing processes MCQs on grinding wheel concepts, surface finishing operations, electrochemical, laser beam, ultrasonic, abrasive jet and other unconventional machining methods.
10. Manufacturing Processes Multiple Choice Questions on Metrology, Welding, Fusion-Welding Processes and Unconventional Welding Methods
The section contains manufacturing processes multiple choice questions and answers on metrology and welding basics, gas, arc and resistance welding, gas cutting, fusion welding processes and other unconventional welding methods.
11. Manufacturing Processes MCQ on Powder Metallurgy, NC Part Programming and Metal Casting and Gating Systems
The section contains manufacturing processes questions and answers on casting fundamentals, powder metallurgy operations, casting processes, patterns and moulding, metal casting defects and expendable mold pattern processes.
12. Manufacturing Processes Multiple Choice Questions on Forming, Metal Forming Processes and Heat Transfer
The section contains manufacturing processes MCQs on forming, forging, forging and shearing operations, metal casting, solidification and fluid flow, foundry automation and heat transfer.
13. Manufacturing Processes MCQ on Jigs and Fixture, Applications and Gears
The section contains manufacturing processes multiple choice questions and answers on jigs, fixtures, computer aided manufacturing and integrated manufacturing, quality assurance and process automation.
Wish you the best in your endeavor to learn and master Manufacturing Engineering - I!