Manufacturing Processes Questions and Answers – Ultrasonic Machining – 2

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This set of Manufacturing Processes Multiple Choice Questions & Answers (MCQs) focuses on “Ultrasonic Machining – 2”.

1. Which of the following materials is not used as abrasive in ultrasonic machining?
a) SiC
b) Boronsilicarbide
c) Diamond
d) TiC
View Answer

Answer: d
Explanation: Abrasive materials used as abrasive in USM are as follows;
• Al2O3
• SiC
• B4C
• Boronsilicarbide
• Diamond.
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2. Pick the odd one out.
a) Frequency of vibration
b) Abrasive size
c) Coolant flow rate
d) Flow strength of work material
View Answer

Answer: c
Explanation: The process parameters which govern the ultrasonic machining process are listed below;
• Amplitude of vibration – 15 – 50 μm
• Frequency of vibration – 19 – 25 kHz
• Feed force – related to tool dimensions
• Feed pressure
• Abrasive size – 15 μm – 150 μm
• Flow strength of work material
• Flow strength of the tool material
• Contact area of the tool
• Volume concentration of abrasive in water slurry
• Abrasive material.

3. Which of the following is not the component of USM machine?
a) Slurry delivery
b) Transducer
c) Concentrator
d) Lead screw
View Answer

Answer: d
Explanation: The typical elements of a USM are as follows;
• Slurry delivery and return system
• Feed mechanism to provide a downward feed force on the tool during machining
• The transducer, which generates the ultrasonic vibration
• The horn or concentrator.

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4. In USM, horn is used for amplifying the vibrations.
a) True
b) False
View Answer

Answer: a
Explanation: The horn or concentrator in USM mechanically amplifies the vibration to the required amplitude of 15 – 50 μm and accommodates the tool at its tip.

5. The transducer for USM works on how many principles?
a) 2
b) 3
c) 4
d) 5
View Answer

Answer: b
Explanation: The ultrasonic vibrations are produced by the transducer. The transducer is driven by suitable signal generator followed by a power amplifier. The transducer for USM works on the following principle
• Piezoelectric effect
• Magnetostrictive effect
• Electrostrictive effect.
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6. The horn or concentrator can have how many different shapes?
a) 2
b) 5
c) 3
d) It can have any shape
View Answer

Answer: c
Explanation: The horn or concentrator is a wave-guide, which amplifies and concentrates the vibration to the tool from the transducer. The horn or concentrator can be of different shape like
• Tapered or conical
• Exponential
• Stepped.

7. Which of the following is not machined by USM?
a) Brittle metals
b) Glass
c) Ceramics
d) Ductile materials
View Answer

Answer: d
Explanation: USM is used for machining;
• hard metallic alloys
• brittle metallic alloys
• semiconductors
• glass
• ceramics
• carbides.

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8. For which of the following operations USM is not used?
a) Round shaped hole
b) Square shaped hole
c) Irregular shaped hole
d) Boring
View Answer

Answer: d
Explanation: USM is used for machining;
• round shaped holes
• square shaped holes
• irregular shaped holes
• surface impressions.

9. USM has low material removal rate.
a) True
b) False
View Answer

Answer: a
Explanation: Limitations of USM are as follows;
• Low MRR
• Rather high tool wear
• Low depth of hole.

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10. USM machine uses _____ axis table.
a) single
b) 2
c) 3
d) 5
View Answer

Answer: b
Explanation: The basic mechanical structure of a USM is very similar to a drill press. However, it has additional features to carry out USM of brittle work material. The workpiece is mounted on a vice, which can be located at the desired position under the tool using a 2 axis table. The table can further be lowered or raised to accommodate work of different thickness.

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Manish Bhojasia - Founder & CTO at Sanfoundry
Manish Bhojasia, a technology veteran with 20+ years @ Cisco & Wipro, is Founder and CTO at Sanfoundry. He is Linux Kernel Developer & SAN Architect and is passionate about competency developments in these areas. He lives in Bangalore and delivers focused training sessions to IT professionals in Linux Kernel, Linux Debugging, Linux Device Drivers, Linux Networking, Linux Storage, Advanced C Programming, SAN Storage Technologies, SCSI Internals & Storage Protocols such as iSCSI & Fiber Channel. Stay connected with him @ LinkedIn | Youtube | Instagram | Facebook | Twitter