JNTU
JNTU B.Tech IV UNCONVENTIONAL MACHINING PROCESSES Previous Question Paper (June - 2024 - R16)
i) Question paper consists of Part A, Part B. ii) Part A is compulsory, which carries 25 marks. In Part A, Answer all questions. iii) In Part B, Answer any one question from each unit. Each question carries 10 marks and may have a, b as sub questions.
Part A
What is the need for the development of non-traditional machining methods?
Answer
Non-traditional machining methods were developed to overcome the limitations of conventional machining processes, specifically when dealing with materials that are extremely hard, brittle, or possess high strength-to-weight ratios, such as superalloys, ceramics, and composites. These methods are necessary because conventional tools often fail to machine these materials effectively due to excessive tool wear, high cutting forces, or the inability to produce complex, intricate geometries and deep, small-diameter holes with high precision and superior surface finish.
List out the recent developments in ultrasonic machining.
Answer
Recent developments in ultrasonic machining (USM) focus on enhancing material removal rates, precision, and the capability to machine advanced materials. Key advancements include:
- Rotary Ultrasonic Machining (RUM): This hybrid process combines the material removal mechanisms of diamond grinding and ultrasonic vibration, significantly improving drilling efficiency and surface finish in hard, brittle materials like ceramics and composites.
- Ultrasonic Assisted Turning/Milling: Integrating ultrasonic vibration into conventional machining tools reduces cutting forces, lowers tool wear, and improves the surface integrity of difficult-to-cut alloys.
- Micro-USM: Advancements in transducer design and tool fabrication have enabled the machining of micro-scale features with high aspect ratios, essential for MEMS and precision electronics.
- Advanced Abrasive Slurry Systems: Development of eco-friendly, high-viscosity, and chemically active slurries has improved the efficiency of material removal and reduced environmental impact.
List out the limitations of abrasive jet machining.
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What are the applications of chemical machining?
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What are the basic characteristics expected from the tool electrode material of EDM process?
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List out the applications of Wire EDM process.
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What is the role of magnetic coils in electronic beam machine?
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Comment about the accuracy of cut obtained using laser beam.
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What are the limitations of plasma arc machining?
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What are the advantages of magnetic abrasive finishing?
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Part B
Explain the role of electrical parameters in the selection of non-traditional machining for a given application.
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Discuss the influence of various parameters on the metal removal rate in ultrasonic machining.
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Give the complete classification of non-traditional machining methods.
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Give the functional description of various elements of an ultrasonic machine.
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List out the process variables of water jet machining. Explain their importance.
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Derive an equation for material removal rate in ECM.
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With the help of line diagram, explain the basic mechanism of metal removal in abrasive jet machining.
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Comment about the surface finish obtained in ECM.
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With the help of a neat sketch, explain the mechanism of metal removal in electric discharge grinding.
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Explain the characteristics of spark eroded surface.
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Draw the R-L-C circuit of EDM and explain how its helps in spark generation and discharge.
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Compare and contrast EDM and Wire EDM.
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Discuss the limitations of electron beam machining.
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Compare and contrast thermal and non-thermal processes.
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Discuss the limitations of laser beam machining.
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Explain the basic steps involved in the generation of electron beam.
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Explain the use of plasma in manufacturing industry.
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What is electro stream drilling? Explain in detail.
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Explain the applications of shaped tube electrolyte machining.
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Explain the accuracy and surface finish obtained in plasma arc machining.
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