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Chemical Machining- PCM , ECM , ECH, ECG - Interview Mechanical Engineering question and answer , viva ,oral examination...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/chemical-machining-pcm-ecm-ech-ecg-interview-question-and-answers/" aria-label="View Post: Chemical Machining- PCM , ECM , ECH, ECG  |  Interview Question and answers">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Chemical Machining- PCM , ECM , ECH, ECG  |  Interview Question and answers","url":"\/\/www.gunkrazy.com\/chemical-machining-pcm-ecm-ech-ecg-interview-question-and-answers\/","articleBody":"Chemical Machining- PCM , ECM , ECH, ECG | Interview Question and answers\r\nChemical Machining- PCM , ECM , ECH, ECG - Interview Mechanical Engineering question and answer , viva ,oral examination question and answers\u00a0\r\n\r\n1. What is the principle of Chemical Machining (CHM)?\r\n\r\nChemical attacks metals and etch them by removing small amounts of material from the surface using reagents or etchants.\r\n\r\n2. What are the processing steps in CHM? \r\n\r\nI. Preparing: precleaning\r\nII. Masking : application of chemically resistant material (if selective etching is desired)\r\nIII. Etch: dip or spray exposure to the etchant\r\nIV. Remove Mask: strip remaining mask and clean\r\nV. Finish: inspection and post processing\r\n\r\nRead more :\u00a0What is Chemical Machining- Chemical Milling\r\n\r\n3. What is etch factor?\r\n\r\nRatio of undercut to depth of cut\r\n\r\n4. What are the two major processes in CHM?\r\n\r\n\u2022 Two major CHM processes are:\r\nI. Chemical milling - eroding material to produce blind details \u2013 pockets, channels etc.,\r\nII. Chemical blanking \u2013 for producing details that penetrate the material entirely (holes, slots, etc.)\r\n\r\n5. What is the purpose of etchant used in CHM? Give some examples.\r\n\r\n\u2022 Purpose: to dissolve a metal by turning it into a metallic salt, which then goes into solution\r\n\u2022 Many chemical are available as etchants: FeCl3, Chromic acid, FeNO3, HF, HNO3\r\n\r\n6. What are the criteria used for selection of etchant?\r\n\r\n \tRequired surface finish\r\n \tRemoval rate \r\n \tMaterial type\u00a0\r\n \tdepth\r\n \tType of resist \r\n \tCost\r\n\r\n7. What is the purpose of maskant and how is it classified?\r\n\r\nMaskants (chemically resistant coatings) are used to cover the surfaces which are not to be machined \u2013 does not allow the etchant to react reach and react with work piece to dissolve it.\r\n\r\n8. Based on the techniques of applying maskants, classify them\r\n\r\n\u2022 Cut and peel - Involve the use of relatively thick material which is scribed and removed to create a selective exposure to the etchant - Neoprene, butyl or vinyl-based material is used as maskants\r\n\u2022 Screen printing - A fine mesh silk or stainless steel screen, which has areas blocked-off to allow selective passage of the maskant is used. \r\n\r\n\u2022 Photoresist masks \u2013 materials that produce etchant resistant images by means of photographic techniques.\r\n\r\n9. How are maskants selected?\r\n\r\nSelection of proper maskant for a particular application is accomplished by evaluation of the job with respect to six factors \u2013 chemical resistance, part configuration, quantity of parts, cost, ease of removal and required resolution\r\n\r\n10. What are the applications for CHM and photochemical machining (PCM)?\r\n\r\nCHM is used extensively to etch preformed aerospace parts to obtain maximum strength to weight ratios:\r\n\u2022 Integrally stiffened Titanium engine ducts\r\n\u2022 Spray etching a rotating tube for cruise missile launch tubes\r\n\u2022 Thinning and sizing of a delta booster tank bulkhead\r\n\u2022 Chemical sizing of engine cowl inlet duct skins\r\n\u2022 Undercut on clad aluminium\r\n\r\n11. What are the advantages of CHM and PCM?\r\n\r\n\u2022 Metal removal is completely stress free\r\n\u2022 Complex shapes and deeply recessed areas can be uniformly chemically milled\r\n\u2022 Extremely thin sections can be chemically milled\r\n\u2022 Metal hardness or brittleness is not a factor\r\n\r\n12. What are the limitations of CHM &amp; PCM?\r\n\r\n\u2022 Fillet radius is approximately equal to depth of cut\r\n\u2022 Extremely deep cuts are usually not cost effective\r\n\u2022 A homogenous metal structure is normally required for good results\r\n\u2022 Suitable photographic facilities are not always available\r\n\r\n13. Please identify the principle of ECM. How does it differ from electroplating?\r\n\r\nPrinciple of ECM - electrolysis.\r\n\r\n When a D.C potential is applied across two electrodes separated by a small gap and an electrolyte is pumped through the small gap, the\r\nconstituents of the anode work piece material goes into the solution and not plate on the cathode tool. Electroplating is the reverse of ECM where the cathode is plated by the depleted metal from the anode.\r\n\r\n14. What is Faraday\u2019s first law?\r\n\r\nThe amount of chemical changes produced by an electric current (or the amount of substance deposited or dissolved) is proportional to the quantity of electricity passed.\r\n\r\n15. What is Faraday\u2019s second law?\r\n\r\nThe amount of different substances deposited or dissolved by the same quantity of electricity are proportional to their chemical equivalent weights.\r\n\r\n16. Explain the parameters controlling the MRR in ECM. (Ref. P.N.Rao and Benedict)\r\n\r\nMRR in ECM is primarily controlled by current density. When all other variables are held constant, the tool penetration rate is directly proportional to the current density. Current density is not only controlled by the amount of current but also by the size of the gap between the tool and the workpiece.\r\n\r\nFeed rate: a high feed rate results in a higher MRR. It also decreases the equilibrium machining gap resulting in improvement of the surface finish and tolerance control\r\nThe velocity and the electrolyte flow through the gap is also an important parameter affecting the surface finish and removal rate\r\n\r\n17. What are the various process parameters of ECM?\r\n\r\nThe process parameters that have a control on the performance of the ECM process is: Feed rate, current density, voltage, electrolyte concentration (low concentration of the electrolyte decreases the machining gap and results in a better surface finish and finer tolerance control) and electrolyte temperature (low temperature of the electrolyte is conducive to a better surface finish and tolerances), velocity and flow of electrolyte.\r\n\r\nElectro Chemical Machining Diagram -Parameter, Advantages and Disadvantages\r\n\r\n18. What are the various process characteristics of the ECM?\r\n\r\n \tMaterial Removal Rate \u2013 the MRRs with ECM are sufficiently large and comparable with that of the conventional methods. MRR of 16m3 \/min for 10,000 A is generally obtained in ECM .\r\n \tSurface finish \u2013 under certain conditions, ECM can produce surface finishes of the order of 0.4 m\r\n \tAccuracy \u2013 under ideal conditions and with properly designed tooling, ECM is capable of holding tolerance of the order of \uf0b1 0.02mm and less.\r\n\r\n19. What are the various tool materials that can be used effectively with ECM?\r\n\r\nGenerally aluminium, copper, brass, titanium, cupro-nickel and stainless steel are used as tool materials.\r\n\r\n20. What factors should be considered in selecting the tool materials in ECM?\r\n\r\n \tHigh thermal and electrical conductivity\r\n \tGood stiffness- Rigidity of the tool construction and material is important because the high pressure can cause deflection of the tool\r\n \tEasy machinability- particularly important if complex shaped tools are required\r\n \tHigh corrosion resistance- to protect itself from the highly corrosive electrolyte solution\r\n\r\n21. What are the different types ECM operations?\r\n\r\n \tElectro Chemical Milling (ECM)\r\n \tElectro Chemical Grinding (ECG)\r\n \tElectro Chemical Honing (ECH)\r\n \tElectro Chemical Deburing (ECD)\r\n \tElectro chemical turning (ECT)\r\n \tElectro chemical trepanning (ECTr) etc.,\r\n\r\nRead more :Electro Chemical Machining -Parameter, Advantages and Disadvantages\r\n\r\n22. Enumerate some typical examples where ECM process can be effectively adopted.\r\n\r\n \tDeep hole drilling having L\/D&gt;20\r\n \tContouring operations in the die blocks\r\n \tThrough cutting and through cavities\r\n\r\n23. What are the different applications of ECM?\r\n\r\n \tAerospace industries: machining gas turbine blades, airframe component fabrication, honey-comb aircraft panels, jet engine blade airfoils\r\n \tManufacture of general machine parts: thin wall mechanical slotting, difficult to machine hollow shafts, chain pinions, internal profile of internal cams, driving joints, pump glands and impellers, connecting rod, hydraulic spools, gear wheels\r\n \tFacing and turning complex 3D surfaces\r\n \tCutting off\r\n\r\n24. What are the advantages of the ECM process?\r\n\r\nLong tool life\r\nMachines complicated shapes in single pass\r\nMachines any material hardness \u2013 independent of physical and mechanical properties\r\nNo burrs\r\nNo stress\r\nGood surface finish\r\nGood accuracy\r\n\r\n25. What are the limitations of the ECM process?\r\n\r\nWork must be electrically conductive\r\nHigh maintenance\r\nCan cause intergranular attack (IGA)\r\nHigh tooling and set-up costs\r\n\r\n26. For which type of work, ECM is useful?\r\n\r\nECM is suitable for hard and difficult to machine materials and when complex shapes are required which are not machinable by conventional methods.\r\n\r\n27. What is ECG? Identify its applications.\r\n\r\nECG is a process that combines the ECM with the mechanical grinding operation to remove material. It uses a grinding wheel with an electrically conductive abrasive bonding agent.\r\n\r\nApplications:\r\n\r\n \tSingle largest use for ECG is in the manufacturing and remanufacturing of turbine blades and vanes for aircraft turbine engines\r\n \tGrinding of tungsten carbide tool inserts\r\n \tRe-profiling worn locomotive traction motor gears\r\n \tBurr-free sharpening of hypodermic needles\r\n \tMachining of fragile or very hard and tough material \u2013 honey comb, thin walled tubes and skins\r\n \tHigh MRR\u2019s when grinding hard, tough, stringy, work-hardenable or heat sensitive materials\r\n\r\n28. Identify any two advantages and limitations of electrochemical grinding (ECG)\r\n\r\nAdvantages\r\n\u2022 No thermal damage to workpiece\r\n\u2022 Elimination of grinding burn\r\n\u2022 Absence of work hardening\r\n\u2022 Long-lasting wheels \u2013 less truing\r\n\u2022 Higher MRR;\r\n\u2022 Single pass grinding - reduced cost of grinding;\r\n\u2022 Absence of burrs on the finished surface;\r\n\u2022 Improved surface finish with no grinding scratches;\r\n\u2022 Reduced pressure of work against the wheel \u2013 no distortion;\r\n\u2022 In ECG, the ECM action is efficient\r\n\r\nLimitations\r\n\r\n \tHigh capital cost \/ Higher cost of grinding wheel;\r\n \tCorrosive environment\r\n \tHigh preventive maintenance cost\r\n \tTolerance achieved are low;\r\n \tDifficult to optimize due to the complexity of the process;\r\n \tNon-conductive materials cannot be machined\r\n\r\n29. What is ECH? Identify its applications.\r\n\r\nECH is a process in which the metal removal capabilities of ECM are combined with the accuracy capabilities of honing. The process consists of a rotating and reciprocating tool inside a cylindrical component.\r\nApplications: the process is easily adaptable to cylindrical parts for trueing the inside surfaces.\r\n\r\nREAD MORE :\u00a0Electrochemical Honing ( ECH ) | Advantages and Disadvantages\r\n\r\n30. What is ECD? Identify its applications.\r\n\r\nECD is a process for the removal of metal burrs by anodic dissolution, the same principle as ECM.\r\n\r\nApplications:\r\n\r\n \tGenerally employed for far away located as well as inaccessible places where other deburring processes are not effective.\r\nECD process has been successfully applied in many different industries ranging from consumer appliances and automotive to biomedical and aerospace products\r\n \tThe automotive industry, a heavy user of ECD, employs this process for deburring and radiusing the crossholes in crankshafts.\r\nNot only is ECD applicable to the high-volume environment of the automotive industry, but it is also applicable to the automated factory.\r\n\r\n31. How does ECD differ from ECM?\r\n\r\nECD is a special version of ECM used exclusively to deburr or radius workpieces. It differs from ECM in that the electrolyte pressure, electrolyte flow, and current are all relatively low. Another major difference is that the cathode (tool) is usually held stationary in ECD.\r\n\r\n32. ECD is same as ECM except much simple to use. Justify the statement.\r\n\r\nECD is same as ECM except much simple to use because, there is no feed mechanism needed for the ECD tool (the tool is held stationary). Moreover in ECD, the electrolyte pressure, electrolyte flow, and current are all relatively low.\r\n\r\n33.. What are the functions served by the electrolyte in the ECM process?\r\n\r\n \tMedium for current to flow\r\n \tTakes away heat generated\r\n \tRemoves reaction products","headline":"Chemical Machining- PCM , ECM , ECH, ECG  |  Interview Question and answers","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-15","mainEntityOfPage":"False","dateModified":"February 22, 2020","image":{"@type":"ImageObject","url":"","height":0,"width":0},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/electrochemical-honing-ech-advantages-and-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/electrochemical-honing-300x251.jpg')"></div><span class="sr-only">link to Electrochemical Honing &#8211; Diagram, Working, Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/electrochemical-honing-ech-advantages-and-disadvantages/">Electrochemical Honing &#8211; Diagram, Working, Advantages and Disadvantages</a></p></header><div class="excerpt"><p>Electrochemical Honing ( ECH ) 
Introduction to Electrochemical Honing :  ECH is a process in which the metal removal capabilities of ECM are combined with the accuracy capabilities of honing....</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/electrochemical-honing-ech-advantages-and-disadvantages/" aria-label="View Post: Electrochemical Honing &#8211; Diagram, Working, Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Electrochemical Honing &#8211; Diagram, Working, Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/electrochemical-honing-ech-advantages-and-disadvantages\/","articleBody":"Electrochemical Honing ( ECH )\u00a0\r\nIntroduction to Electrochemical Honing :\r\n\r\n \tECH is a process in which the metal removal capabilities of ECM are combined with the accuracy capabilities of honing. The process consists of a rotating and reciprocating tool inside a cylindrical component.\r\n \tMaterial is removed through anodic dissolution and mechanical abrasion \u2013 8% or more, of the material removal, occurs through electrolytic action\r\n \tAs with conventional ECM, the workpiece is the anode and a stainless steel tool is the cathode.\r\n\r\nRead More: What is Chemical Machining-Chemical Milling\r\n\r\n electrochemical honing\r\nECH tool construction\r\n\r\n \tTool consists of a hollow stainless steel body that has expandable, nonconductive honing stones protruding from at least three locations around the circumference\r\n \tThe honing stones are identical with those used in conventional honing operations, except that they must resist the corrosiveness of the electrolyte\r\n \tThe honing stones are mounted on the tool body with a spring-loaded mechanism so that each of the stones exerts equal pressure against the workpiece\r\n \tThe length of the stones is selected to be approximately one-half of the length of the bore being processed.\r\n\r\nWorking of electrochemical honing :\u00a0\r\n\r\n \tAt the beginning of the ECH cycle, the stones protrude only 0.075-0.127mm from the stainless steel body, establishing the gap through which the electrolyte flows\r\n \tThe electrolyte enters the tool body via a sliding inlet sleeve from which it exits into the tool-workpiece gap through small holes in the tool body\r\n \tAfter passing through the gap, the electrolyte flows from the workpiece through the gap at the top and bottom of the bore\r\n \tThe mechanical action of the tool is the same as with conventional honing; the tool is rotated and reciprocated so that the stones abrade the entire length of the bore\r\n \tElectrolytes used in ECH are essentially the same as those used in ECM, although the control of pH, composition and sludge is less critical because the abrasive action of the stones tends to correct any resulting surface irregularities\r\n \tAs in ECM, the electrolytes are recirculated and reused after passing through appropriate filtration, and the most commonly used electrolytes are sodium chloride and sodium nitrate.\r\n\r\nProcess parameters of electrochemical honing :\r\n\r\n \tMachines are available that deliver up to 6000 amp\r\n \tCurrent density at the workpiece can range from 12 to 47amp\/cm 2\r\n \tWorking voltages are 6-30 VDC\r\n \tThe electrolyte is delivered to the work area at pressures of 0.5-1 MPa\r\n \tECH can remove materials at rates up to 100% faster than conventional honing, the gain being more pronounced as the material hardness increases\r\n \tMachine capacities are currently able to accommodate bore lengths up to 600 mm and bore diameters from 9.5 to 150 mm.\r\n\r\nAdvantages of electrochemical honing :\u00a0\r\n\r\n \tIncreased MRR particularly on hard materials\r\n \tSince most of the material is removed electrochemically, honing stone life is greatly extended\r\n \tBurr-free operation\r\n \tUnlike conventional honing, no micro-scratches are left on the work surface\r\n \tLess pressure required between stones and work\r\n \tReduced noise and distortion when honing thin-walled tubes\r\n \tCooler action leading to increased accuracy with less material damage\r\n \tAs with all ECM-based processes, ECH imparts no residual stresses in the workpiece\r\n \tCapable of achieving surface finishes of 0.05\u03bc and dimensional accuracies of \u00b10.012mm\r\n \tBy turning off the power to the tool before the end of the honing cycle, the stones can be used in a conventional manner to achieve tolerances of \u00b10.002mm and to impart a compressive residual stress on the work surface.\r\n\r\nLimitations of electrochemical honing :\u00a0\r\n\r\n \tHigh capital cost\r\n \tCorrosive environment\r\n \tHigh preventive maintenance cost\r\n \tNon-conductive materials cannot be machined\r\n \tRequires disposal and filtering of electrolytes","headline":"Electrochemical Honing &#8211; Diagram, Working, Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-15","mainEntityOfPage":"False","dateModified":"May 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/electrochemical-honing-300x251.jpg","height":251,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/abrasive-jet-machining-interview-question-and-answers/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/abrasive-jet-machining-300x147.jpg')"></div><span class="sr-only">link to Abrasive jet machining | interview question and Answers</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/abrasive-jet-machining-interview-question-and-answers/">Abrasive jet machining | interview question and Answers</a></p></header><div class="excerpt"><p>Abrasive jet machining | interview question and Answers
Abrasive jet machining -interview ,viva, oral question and answers for Mechanical students   1. What is the principle behind abrasive jet...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/abrasive-jet-machining-interview-question-and-answers/" aria-label="View Post: Abrasive jet machining | interview question and Answers">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Abrasive jet machining | interview question and Answers","url":"\/\/www.gunkrazy.com\/abrasive-jet-machining-interview-question-and-answers\/","articleBody":"Abrasive jet machining | interview question and Answers\r\nAbrasive jet machining -interview ,viva, oral question and answers for Mechanical students\u00a0\r\n\r\n1. What is the principle behind abrasive jet machining?\r\n\r\nA jet of inert gas consisting of very fine abrasive particles strikes the work piece at high velocity (usually between 200-400 m\/sec) resulting in material removal through chipping \/ erosive action.\r\n\r\nSee also :\u00a0Difference between Conventional and Non-Conventional Machining Process\r\n\r\n2. What is the mechanism of material removal in AJM?\r\n\r\nErosion. Abrasive jet machining removes material through the action of a focused stream of abrasive-laden gas\r\n\r\n3. What are the major subsystems of AJM?\r\n\r\nAJM system consists of four major subsystems:\r\n\r\n \tGas propulsion system\r\n \tMetering system\r\n \tDelivery system\r\n \tAbrasive collection system\r\n\r\nabrasive jet machining\r\n\r\n4. Why the abrasive particles not reused in the AJM?\r\n\r\nDuring the process, abrasive particles get contaminated with different gases used in the process, affecting their cutting efficiency; Also the cutting capacity decreases after the first application. Further, cost of the abrasive is also low.\r\n\r\n5. Why is AJM not suitable for soft materials?\r\n\r\nAbrasive particles used in AJM can penetrate and embed with soft materials.\r\n\r\n6. Name the abrasive materials that are used for the AJM.\r\n\r\nThe common abrasives used for the AJM process are:\r\n\r\n \tDolomite\r\n \tSodium Bicarbonate\r\n \tGlass beads\r\n \tSilicon carbide\r\n \tSilicon Nitride\r\n \tAlumina\r\n\r\nSee also ;\u00a0Seminar | Abrasive Jet Machining full report Download\r\n\r\n7. Mention the abrasives used for different applications\r\n\r\nAluminium oxide - Cleaning, cutting and deburring\r\nSilicon carbide - As above but for harder materials\r\nGlass beads - Matt polishing, cleaning\r\nCrushed-\u00a0 glass Peening, cleaning\r\nSodium bicarbonate-\u00a0 Cleaning, cutting for soft materials\r\n\r\n8. Name different gases used in AJM. Which of this is most widely used?\r\n\r\nDry air\r\nCarbon-di-oxide\r\nNitrogen\r\nHelium\r\nAir is most widely used owing to easy availability and little cost.\r\n\r\n9. What is the effect of the grain size on the material removal rate (MRR) in the AJM?\r\n\r\nFiner grain sizes are less irregular in shape, and hence, posses lesser cutting ability. Moreover, finer grains tend to stick together and choke the nozzle. The most favourable grain sizes range from 10 to 50m. Larger particle sizes remove the material faster.\r\n\r\n10. What is the effect of jet velocity on the MRR in AJM?\r\nThe kinetic energy of the abrasive jet is utilised for metal removal by erosion. The jet velocity is a function of the nozzle pressure, nozzle design, abrasive grain size and the mean number of abrasives per unit volume of the carrier gas. In general with increase in the jet\r\nvelocity, the MRR increases.\r\n.\r\n11. Define mixing ratio. What is the effect of mixing ratio on the MRR?\r\n\r\nMixing ratio is the ratio of the volume flow rate of the abrasive per unit time to the volume flow rate of the carrier gas per unit time. A large value of mixing ratio should result in higher rates of MRR but a large abrasive flow rate has been found to adversely influence jet velocity and may sometimes even clog the nozzle.\r\n\r\n12. What is the effect of the abrasive powder flow rate on the MRR in AJM?\r\n\r\nIncreasing the flow rate increases the removal rate because more abrasive particles are available for cutting. However as the powder flow rate is increased, the mass fraction of abrasive in the jet is also increasing. As the mass fraction increases, the abrasive velocity decreases, thus reducing the removal rate.\r\n\r\n13. What are common materials used for the nozzle in AJM?\r\n\r\nSapphire and tungsten carbide are the common materials for the nozzle.\r\n\r\n14. Why are masks used in AJM? Which material is used for fabrication of masks?\r\n\r\nMasks are used to control over spray or to produce large holes and intricate detail without having to move the nozzle and trace the shape. Masks can be fabricated from rubber or metal, each having its advantage and disadvantage. While the rubber masks are easy to fabricate, they give poor edge definition. The metal masks give much better definition but erode faster.\r\n\r\n15. Mention the process capabilities (process characteristics) of AJM\r\n\r\n \tLow MRR\r\n \tIntricate details can be produced\r\n \tNarrow slots\r\n \tLow tolerances\r\n \tMinimization of taper\r\n \tThin-sectioned, brittle material, inaccessible areas\r\n \tAlmost no surface damage\r\n\r\n16. What are the advantages and limitations of AJM?\r\n\r\nAdvantages:\r\n\r\n \tMachining of very hard materials\r\n \tHeat sensitive materials can be machined \u2013 the gas stream dissipates generated heat when cutting heat-sensitive materials\r\n \tFragile materials can be machined \u2013 the small loads transmitted to the workpiece allow the cutting of fragile pieces\r\n \tVery low capital cost and low power consumption\r\n \tNo part shatter or vibration\r\n \tThe nozzle can be directed towards small, difficult-to-reach areas\r\n\r\nLimitations:\r\n\r\n \tLow material removal rate\r\n \tStray cutting can occur and hence accuracy is not good\r\n \tExcessive taper on deep cuts may also be a disadvantage, although the amount of taper can be reduced by tilting the nozzle\r\n \tShort nozzle standoff when used for cutting\r\n \tPossibility of abrasive particles becoming embedded in the workpiece\r\n \tNozzle wear rate is high\r\n \tProcess tends to pollute the environment\r\n\r\n17. Mention some typical applications of AJM in engineering.\r\n\r\n \tRemoving flash and parting lines from injection moulded parts\r\n \tDeburring and polishing plastic, nylon and teflon components\r\n \tCleaning metallic mould cavities which otherwise may be inaccessible\r\n \tCleaning oxides from metal surfaces\r\n \tCleaning metallic smears from ceramics\r\n\r\n18. What s the principle of WJM?\r\n\r\nIf a jet of water is directed at a target in such a way that, on striking the surface, the high velocity flow is virtually stopped, then most of the kinetic energy of the water is converted into pressure energy. Erosion occurs when this pressure exceeds the strength of the bond binding together the materials making up the target.\r\n\r\nIntroduction To Water Jet Machining Process | Advantages and Disadvantages\r\n\r\n19. What is the mechanism behind the material removal in WJM?\r\n\r\nRemoves material through the erosion effects of a high velocity, small diameter jet of water.\r\n\r\n20. Name the main elements of the WJM system.\r\n\r\n \tHydraulic unit\r\n \tIntensifier\r\n \tAccumulator\r\n \tFilters\r\n \tWater transmission lines\r\n \tOn\/off valve\r\n \tWaterjet nozzles\r\n \tWaterjet catchers\r\n \tFluid additives\r\n\r\n21. Why WJM is not suitable for brittle materials?\r\n\r\nBrittle materials may crack and break during water jet machining.\r\n\r\n22. Why is glass not machined by WJM?\r\n\r\nGlass is a brittle material that cracks during WJM.\r\n\r\n23. Why is it desirable to keep the standoff distance minimum in the WJM?\r\n\r\nSOD is kept minimum in order to prevent the dispersion of water stream before it strikes the workpiece.\r\n\r\n24. What are the process parameters that control the results achieved with WJM?\r\n\r\nPressure, nozzle diameter, traverse rate and the SOD, all define the process. Of these, SOD is the least critical.\r\n\r\n25. What is the effect of traverse rate on the performance of WJM?\r\n\r\nThicker and denser materials can be cut as the traverse rate decreases. Materials that are too thick to be cut in a single pass can be cut with multiple passes if the first pass can produce a well-defined slot.\r\n\r\n26. What is the function of intensifier in WJM?\r\n\r\nThe intensifier is used to increase the water pressure up to 380MPa \u2013 pressure increase is determined by the ratio of the working areas of the two cylinders.\r\n\r\nRead also :\u00a0Basic Of Unconventional Machining | interview Question and Answers","headline":"Abrasive jet machining | interview question and Answers","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-15","mainEntityOfPage":"False","dateModified":"February 22, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/abrasive-jet-machining-300x147.jpg","height":147,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal no-thumb"><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/basic-of-unconventional-machining-interview-question-and-answers/">Basic Of Unconventional Machining | interview Question and Answers</a></p></header><div class="excerpt"><p>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...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/basic-of-unconventional-machining-interview-question-and-answers/" aria-label="View Post: Basic Of Unconventional Machining | interview Question and Answers">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Basic Of Unconventional Machining | interview Question and Answers","url":"\/\/www.gunkrazy.com\/basic-of-unconventional-machining-interview-question-and-answers\/","articleBody":"Basic Of Unconventional Machining | interview Question and Answers\r\n1. What is the need for unconventional machining processes?\r\nHigh production rate\r\nLow cost of production\r\nBetter surface integrity,\r\nHigh surface finish\r\n\r\n2. What are the characteristics of UCM processes?\r\n\r\nPerformance is independent of strength barrier\r\nUse different kinds of energy in direct form\r\nIn general, low MRR but better quality products\r\nComparatively high initial investment cost\r\n\r\n3.Differentiate the conventional and unconventional machining processes in terms of principles.\r\n\r\nIn 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.\r\n\r\nread also\u00a0 List Of Non Conventional Mechanical Projects 2017\r\n\r\n4. What are the various types of energy sources used in non-traditional machining techniques? Give examples for each.\r\n\r\nPneumatic pressure- AJM\r\nHydraulic pressure- WJM, USM, AWJM\r\nCorrosion- CHM, CHB, PCM\r\nHigh current density in electrolytes- ECM\r\nHigh voltage- EDM (for sparking); IBM, EBM (ionizing); LBM\r\n(creating avalanche in lazing medium);\r\nPAM (for ionizing the plasma gases)\r\n\r\n5. Classify the different types of unconventional machining processes based on the mechanical energy.\r\n\r\nAbrasive Jet Machining (AJM)\r\nWater Jet Machining (WJM)\r\nUltrasonic Machining (USM)\r\nAbrasive Water Jet Machining (AWJM)\r\n\r\n6. Identify the mechanism of material removal, transfer media and energy source for EDM.\r\n\r\nMechanism of material removal- Fusion of materials by arcs\r\nTransfer media - Electron stream\r\nEnergy source - High voltage\r\n\r\nread also\u00a0Development of For Wire Electrical Discharge Machining (WEDM)\r\n\r\n7. Identify the mechanism of material removal, transfer media and energy source for ECM.\r\n\r\nMechanism of material removal- Ion displacement\r\nTransfer media - Electrolyte\r\nEnergy source - High current\r\n\r\n8. Identify the mechanism of material removal, transfer media and energy source for EBM.\r\n\r\nMechanism of material removal- Vaporization\r\nTransfer media - Electron stream\r\nEnergy source - High voltage\r\n\r\nElectron beam machining Diagram\r\n\r\n9. Identify the mechanism of material removal, transfer media and energy source for LBM.\r\n\r\nMechanism of material removal- Vaporization\r\nTransfer media - Amplified coherent light radiation\r\nEnergy source - High voltage\r\n\r\n10. Identify the mechanism of material removal, transfer media and energy source for PAM. \r\n\r\nMechanism of material removal- Vaporization\r\nTransfer media - Ionised gas stream\r\nEnergy source - High voltage\r\n\r\nRead more : Plasma Arc Machining- Process, Diagram , Advantages and Disadvantages\r\n\r\n11. Identify the mechanism of material removal, transfer media and energy source for USM. \r\n\r\nMechanism of material removal- Erosion\r\nTransfer media - High velocity particles\r\nEnergy source - Hydraulic pressure\r\n\r\n12. Identify the mechanism of material removal, transfer media and energy source for AJM. \r\n\r\nMechanism of material removal- Erosion\r\nTransfer media - High velocity particles\r\nEnergy source - Pneumatic pressure\r\n\r\nRead more :Seminar | Abrasive Jet Machining full report Download\r\n\r\n13. Identify the mechanism of material removal, transfer media and energy source for WJM. \r\n\r\nMechanism of material removal- Erosion\r\nTransfer media - High velocity water jet\r\nEnergy source - Hydraulic pressure\r\n\r\nread more :\u00a0Introduction To Water Jet Machining Process | Advantages and Disadvantages","headline":"Basic Of Unconventional Machining | interview Question and Answers","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-15","mainEntityOfPage":"False","dateModified":"February 22, 2020","image":{"@type":"ImageObject","url":"","height":0,"width":0},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/design-and-fabrication-of-automatic-baby-cradle-system/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/design-and-fabrication-of-baby-cradle-machine-300x169.jpg')"></div><span class="sr-only">link to Design and Fabrication of Automatic Baby Cradle System</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/design-and-fabrication-of-automatic-baby-cradle-system/">Design and Fabrication of Automatic Baby Cradle System</a></p></header><div class="excerpt"><p>Design and Fabrication of Automatic Baby Cradle System
Abstract -  Cradle is an appliance which use to carry a baby and oscillate automatically with certain speed for comfort sleep of a baby....</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/design-and-fabrication-of-automatic-baby-cradle-system/" aria-label="View Post: Design and Fabrication of Automatic Baby Cradle System">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Design and Fabrication of Automatic Baby Cradle System","url":"\/\/www.gunkrazy.com\/design-and-fabrication-of-automatic-baby-cradle-system\/","articleBody":"Design and Fabrication of Automatic Baby Cradle System\r\nAbstract -\r\n\r\nCradle is an appliance which use to carry a baby and oscillate automatically with certain speed for comfort sleep of a baby. Babies sleeps sound in mosses baskets or cradle, as they afford a limited sleeping atmosphere which helps them feel secure. B-Care is a novel concept, which enables the movements of a carriage, to raise the cradle, to move the machine from one place to another, automatic movement of cradle when baby is disturbed and much more.\r\n\r\nThe equipment Baby care includes a dc motor, link, and an oscillating bed and sensors. The electric powered motor will actuate the links by shaft. Links actuates the rod attached to the bed at constant speed. The carriage is attached to the metal rod through springs which will provide a vibratory motion. It will also ensure the cradle motion even when the baby cries or moves using sensors. Motor, link and sensors are attached to the side of the cradle frame. High strength, light weight material is used for the manufacturing of Baby care.\r\n\r\nBaby care is the most cost effective, user friendly, automated mechanism for baby care in the modern nuclear family.\r\n\r\nINTRODUCTION\r\n\r\nIn today's world, everyone is busy in its own life. Nowadays, even the mothers are working and there is a requirement of unattended cradle. The proposed E-Cradle is a novel solution to this problem. In the proposed design, there will be a circuit placed along the cradle which will sense the sound intensity of the cry of the child and takes necessary actions based on the sound intensity of the child's cry.\r\n\r\nThe system is designed to help parents and nurses in infants care.\r\n\r\nThe design aims at following points:\r\n\r\n \tCradle starts swinging automatically when baby cry.\r\n \tIf the baby stops crying before 2 minutes, then the cradle will stop automatically after 3 minutes of swinging.\r\n \tSounds an alarm if baby cries for more than a stipulated time of 2 minutes indicating that baby needs attention.\r\n \tSounds an alarm when mattress gets wet.\r\n\r\nBefore the use of cradle in society, baby caring was completely by caretaker but in the nuclear family baby\u00a0caring is very difficult. So there is a need for automation in the cradle section. As the baby needs more care and safety automation of cradle is very much difficult for safe design.\r\n\r\ndesign and fabrication of baby cradle machine\r\n\r\nCost is much important to develop a cradle with an automated mechanism. The family faces the problem of carrying the baby to places for that cradle must be mobile. So the standard living of the reputed family needs the automated cradle. Various small industries uses components made of plastic, rubber etc., assembled mechanically to make simple cradle but when using automation we need material\r\nwith strength and for simple using materials must be weightless. For considering safety of baby sharp edges are covered with rubber. Cradle performance and efficiency is high as it needs less electricity and probability of failure is completely removed.\r\n\r\nSince safety is necessary for baby, care has to be taken during production and assembly of its component parts. Many tools and equipment used in the domestic as well as small scale industries are designed to help the personnel working in production facility. Special instruction books are given to help the care taker for easiness. Our project aims at the design and fabrication of an Electro Mechanical Cradle for the purpose of using it in nuclear family with medium income. The principle used here is that cam which will rotate according to the mechanical power given to it, in our project the carriage is being oscillated with the help of a U-frame which is coupled to a cam which is mechanically powered by motor (low speed high torque motor). Also this device is likely to be used in public places where the family goes.\r\n\r\nEQUIPMENT DESCRIPTION\r\nAn electric motor is a machine which converts electrical energy to mechanical energy. Its action is based on the principle that when a current carrying conductor is placed in a magnetic field, it experiences a magnetic force whose direction is given by Fleming\u2019s left hand rule. When a motor is in operation, it develops torque. This torque can produce mechanical rotation. DC motors are also like generators classified into shunt wound or series wound or compound wound motors.\r\n\r\nWatch Full Animation :\r\n\u00a0\u00a0\r\nReference \/ Download research paper :\r\n\r\nDesign and Fabrication of Automatic Baby Cradle System","headline":"Design and Fabrication of Automatic Baby Cradle System","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-15","mainEntityOfPage":"False","dateModified":"February 22, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/design-and-fabrication-of-baby-cradle-machine-300x169.jpg","height":169,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/cupola-furnace-diagram-and-working-of-cupola/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/cupola-furnace-250x300.jpg')"></div><span class="sr-only">link to Cupola Furnace | Diagram and Working Of Cupola</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/cupola-furnace-diagram-and-working-of-cupola/">Cupola Furnace | Diagram and Working Of Cupola</a></p></header><div class="excerpt"><p>Cupola Furnace | Diagram and Working Of Cupola
CUPOLA:-
It consists of a cylindrical steel shell with its interior lined with heat resisting fire bricks. There is a drop door at the bottom after...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/cupola-furnace-diagram-and-working-of-cupola/" aria-label="View Post: Cupola Furnace | Diagram and Working Of Cupola">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Cupola Furnace | Diagram and Working Of Cupola","url":"\/\/www.gunkrazy.com\/cupola-furnace-diagram-and-working-of-cupola\/","articleBody":"Cupola Furnace | Diagram and Working Of Cupola\r\nCUPOLA:-\r\nIt consists of a cylindrical steel shell with its interior lined with heat resisting fire bricks. There is a drop door at the bottom after closing which proper sand bed could be prepared. This sand bed provides proper refractory bottom for molten metal &amp; coke. Above the sand bed, there is a metal tapping hole which will be initially closed with clay known as \u201dbot\u201d. Opposite &amp; above the metal tapping hole, there is a slag hole where slag is trapped. Above the slag hole, there is a wind box which is connected to air blowers. Air enters to the cupola through the tuyeres. Above the charging platform, there is a charging hole through which charge is put into the cupola. The charge consists of the pig iron, scrap iron, coke and fluxes.\r\n\r\n cupola furnace diagram\r\n\r\nOperation:-\r\nFirst the drop door at the bottom is closed. Sand bed with slope towards tap hole is rammed. Coke bed of suitable height is prepared above the sand bed and is ignited through the tap hole. After proper ignition, alternate layers of charge, flux &amp; coke are fed through the charge door. Then the charge is allowed to soak in the heat and the air blast is turned on. Within 5 to 10mins, the molten metal is collected through the tap hole. When enough metal is collected in the well of the cupola, the slag is drained off through the slag hole. Then the molten metal is collected in the ladles and is transported to the moulds with a minimum time loss.\r\nFluxes are added in the charge to remove the oxides &amp; other impurities present in the metal. The flux commonly used is lime stone (CaCO3) in a proportion of 2 to 4% of the metal charge. Others fluxes used are dolomite, sodium carbonate, calcium carbide. Flux reacts with oxides to form compounds having low melting point and lighter so that it will float on the metal pool.\r\nCharge calculations:-\r\nCarbon:- \r\n\r\nWhen charge comes through the coke bed, some amount of carbon is picked up by the metal depending on the temperature and the time when the metal is in contact with the coke. It is of the order of 0.15% carbon.\r\n\r\nSilicon:- \r\n\r\nIt is Oxidised in the cupola and there will be a loss of 10% silicon. It may be as high as 30%. To increase the silicon content, ferrosilicon is added to the metal.\r\n\r\nManganese:- \r\n\r\nThere is a loss of 15 to 20% manganese during melting process. The content of manganese can be increased by the addition of ferromanganese.\r\n\r\nSulphur- \r\n\r\nThere will a sulphur pick up in a range of 0.03 to 0.05%.\r\n\r\nOther furnaces:\r\n\r\nOther furnaces include\r\n\r\n \tOpen hearth furnace\r\n \tRotary furnace\r\n \tCrucible furnace\r\n \tImmersion heated furnace\r\n\r\nBased on the source of heating, they can be classified as\r\n\r\n \tElectrical heating furnace (arc, resistance or induction)\r\n \tFossil full fired furnace (solid, oil\/gaseous fuel)","headline":"Cupola Furnace | Diagram and Working Of Cupola","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-13","mainEntityOfPage":"False","dateModified":"February 22, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/cupola-furnace-250x300.jpg","height":300,"width":250},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <nav class="pagination-wrapper" aria-label="article pagination"> <a class="prev page-numbers" href="?page_num=106">&laquo; PREV</a> <a class="page-numbers" href="?page_num=1"><span class="screen-reader-text">Page </span>1</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=105"><span class="screen-reader-text">Page </span>105</a> <a class="page-numbers" href="?page_num=106"><span class="screen-reader-text">Page </span>106</a> <span aria-current="page" class="page-numbers current"><span class="screen-reader-text">Page </span>107</span> <a class="page-numbers" href="?page_num=108"><span class="screen-reader-text">Page </span>108</a> <a class="page-numbers" href="?page_num=109"><span class="screen-reader-text">Page </span>109</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=338"><span class="screen-reader-text">Page </span>338</a> <a class="next page-numbers" href="?page_num=108">NEXT &raquo;</a></nav></section></main><aside id="secondary" class="widget-area"><div class="about-wrapper"><h2 class="widget-title" style="background: #d693c6; color: #ff392e">About Us</h2><div class="about-image" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/03/Sachin-Thorat-300x300-min.png')"></div><p class="about-copy">LearnMech.Com is a Mechanical Project-oriented platform run by Sachin Thorat who is a B-Tech Graduate in Mechanical Engineering. 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