b) USM View Answer, 6. d) Increase in number of particle making impact per cycle a) Decrease in volume of work material per impact What is the machinability rate of glass by USM? 9. Material removal rate in USM increases with a) Decrease in volume of work material per impact b) Decrease in volume of work material per impact c) Increases in frequency d) Decreases in the number of particle making impact per cycle View Answer In general, the material removal rate increases with the increase in the abrasive particle size for both aqueous abrasive slurry and oil based abrasive slurry. d) All of the mentioned Material removal rate in USM increases with - 225117. All Rights Reserved. a) Decreases The depth of cylindrical holes is presently limited to 2.5 times the diameter of the tool. (a) 8. 9. c) Transducer As the tool area increases, MRR ____. a) 1 to 10 microns. 2. 7. Answer. 6. d) 30 – 35 % To practice all areas of Manufacturing Engineering, here is complete set of 1000+ Multiple Choice Questions and Answers. List three applications of USM xi. Material removal rate in USM increases with c) decreases, becomes stable and then increases . What happens to MRR with increase in tool amplitude? In USM, high frequency electrical energy is converted into mechanical vibrations via a transducer/booster combination which are then transmitted to an energy focusing as well as amplifying device: horn/tool assembly. The rate of material removal in USM depends on ____. b) Decreases c) Decrease in frequency The rate of material removal in USM depends on ____. The mrr tends to be somewhat lower than the theoretically-predicted value. ULTRASONIC MACHINING PROCESS (USM) BY, ARAVINDKUMAR B 2. It was noticed that the evidence of three body material removal mechanism is predominant for micro USM using oil based slurry. In this research paper, the Finite Element Analysis is used for the investigation. ULTRASONIC MACHINING PROCESS (USM) Ultrasonic machining (USM) is a mechanical material removal process. It is found that the material removal rate generally increases with the decrease of the material fracture toughness. a) True b) False View Answer. b) Benzene All Rights Reserved. In Ultrasonic Machining (USM) the material removal rate would (a) increase (b) decrease (c) increase and then decrease (d) decrease and then increase With increasing mean grain diameter of the abrasive material. View Answer, 7. Also, material removal rate is an important performance variable in USM machining. 5. Stationary USM Set Up . View Answer, 7. The device for converting any type of energy into ultrasonic waves is the ultrasonic transducer. 7. Static load on tool: The material removal rate increase with the static load on tool up to a maximum value. a) Conductors Faraday's law states that the material removal rate is proportional to the machining current. The Nozzle The nozzle is one of the most vital elements controlling the process characteristics . Join our social networks below and stay updated with latest contests, videos, internships and jobs! This can be explained on the basis of the Machining rate obtained with different tool materials. b) False In general, the material removal rate increases with the increase in the abrasive particle size for both aqueous abrasive slurry and oil based abrasive slurry. d) None of the mentioned a) True 3. It is found that the material removal rate generally increases with the decrease of the material fracture toughness. Material Removal Rate (MRR), otherwise known as Metal Removal Rate, is the measurement for how much material is removed from a part in a given period of time. ____ can be used as abrasive carrying medium. Beyond this point, the material removal decreases with the increasing static load. b) 15 – 20 % View Answer, 9. Sanfoundry Global Education & Learning Series – Manufacturing Engineering. The MRR increases with increase in speed of rotation of workpiece. Material removal rate in USM increases with d) None of the mentioned 7. Which of the following elements of USM is used to apply working force during machining operation? d) Decreases in the number of particle making impact per cycle This implies that tool … Answer: b Explanation: Splashing occurs if amplitude is very high which in turn decreases the material removal rate. 4. b) 10 to 50 microns. May 11 2015 06:52 AM 1 Approved Answer Akshay answered on July 24, 2016 abrasive increases the material removal rate also increases. In Ultrasonic Machining (USM) the material removal rate would (a) increase (b) decrease (c) increase and then decrease (d) decrease and then increase with increasing mean grain diameter of the abrasive material. View Answer, 8. It is used to erode material in the form of fine holes and cavities in hard or brittle workpiece through the use of formed tools, vibrations of high frequency along with the … b) Electron beam machining Machining rate can be affected by the ratio of hardness of tool to that of hardness of work piece. Gas-As the velocity pressure depends on the composition of gas, the material removal rate is mainly affected by the composition of the gas. b) Torque If splashing occurs, it will result in an increase of material removal rate in USM. c. fracture of work material due to impact of grains d. none of the above Answer Explanation At a particular pressure the material removal rate increases with the abrasive flow rate but after reaching an optimum value, the material removal rate decreases with the further increase in abrasive flow rate. a) Increases c) Increase and then decrease 1 Answer to In Ultrasonic Machining (USM) the material removal rate would (a) increase (b) decrease (c) increase and then decrease (d) decrease and then increase With increasing mean grain diameter of the abrasive material. Although, the frequency of vibration is not considered a major influencing parameter in USM operations because the user rarely varies the frequency over a wide range, however, higher frequency increases material removal rate. There is an optimum mixing ratio (mass fraction of the abrasive in the jet) for which the metal removal rate is the highest. d) None of the mentioned (b) 6. Ans: The various process Parameters that control MRR in USM process are: (i) Frequency: The material removal rate (mrr) increases linearly with the frequency but in actual characteristic is not exactly linear. a) Water 2. The microstructure and localized fracture mechanism of materials seem … b) 10 to 50 microns. With increasing feed force, the MRR exhibits the following behavior: (A) increases linearly (B) decreases linearly (C) does not change (D) first increases and then decreases; Show Answer . The lowest tool wear has been recorded for titanium alloy (ASTM Grade –V). c) 0.08 – 0.10 mm As the concentration of particle increases the material removal rate initially increases and then decreases. d) Decrease and then increase Linear material removal rate -0.025 to 25mm/min 6. d) Decrease up to a limiting condition View Answer, 8. When the static pressure of the feed is increases, what happens to MRR? The maximum metal removal rate is 3 mm®/s and the power consumption is high. Which of the following is an unconventional process of machining? This effect appears to be more pronounced in the machining of brittle materials than in the ductile ones. Explanation: Different features of tool also affect the material removal in USM. Analyse the effect of process parameters on material removal rate (MRR) v. Develop mathematical model relating MRR with USM parameters vi. Polycarbonate (UL-752) Glass and USM Tool. 2. Draw variation in MRR with different process parameters vii. advertisement. a) True However, a more cost-effective method for machining ceramic components is needed [4]. The Gas The AJM unit normally operates at a pressure of 0.2-1.0 N/mm 2. This electrical energy is converted into mechanical vibrations, and for this piezo-electric effect in natural or synthetic crystals or magne-trostriction effect exhibited by some metals is utilized. During the electrochemical machining (ECM) of iron (atomic weight = 56, valency = 2) at current of 1000 A with 90% current efficiency, the material removal rate was observed to be 0.26 gm/s. 1.In abrasive jet machining, as the distance between the nozzle tip and the work surface increases, the material removal rate. b) Decreases proaches to increase the material removal rate or reduce tool wear in case of titanium or its alloy were presented [3]. Machinability rate of glass by USM is ____. When the static pressure of the feed is increases, MRR ____. ____ can be used as abrasive carrying medium. b) Feeding unit One of the first places these machinists turn is to MRR, which encompasses Radial Depth of Cut … 1. Material removal rate in USM increases with here is complete set of 1000+ Multiple Choice Questions and Answers, Prev - Advanced Machining Questions and Answers – USM – Material Removal, Next - Advanced Machining Questions and Answers – USM – Dimensional Accuracy and Surface Quality, Machine Design Questions and Answers – Copper Alloys & Die Casting Alloys, Machine Design Questions and Answers – Ceramics & Plastics, Chemical Process Calculation Questions and Answers, Manufacturing Engineering / Processes I Questions and Answers, Manufacturing Engineering / Processes II Questions and Answers, Machine Tools & Machining Questions and Answers, Advanced Machining Processes Questions and Answers, Advanced Machining Questions and Answers – ECM-Process Control, Advanced Machining Questions and Answers – ECM-Advantages and Disadvantages, Advanced Machining Questions and Answers – Water Jet Machining – Introduction and Machining system, Advanced Machining Questions and Answers – WJM – Process Parameters and Material removal, Advanced Machining Questions and Answers – USM – Material Removal, Advanced Machining Questions and Answers – Ice Jet Machining, Advanced Machining Questions and Answers – Ultrasonic Machining – Introduction, Manufacturing Engineering Questions & Answers – Other Unconventional Machining, Advanced Machining Questions and Answers – AJM – Applications, Advantages and limitations, Advanced Machining Questions and Answers – MAF – Machining System, Advanced Machining Questions and Answers – Non Traditional Machining, Manufacturing Engineering Questions & Answers – Abrasive jet Machining, Advanced Machining Questions and Answers – AWJM – Process Capabilities, Manufacturing Engineering Questions & Answers – Ultrasonic Machining, Advanced Machining Questions and Answers – Abrasive Jet Machining – Introduction and Machining system. a) Increases Rotary ultrasonic machining (RUM) was developed as an alternative to USM. 6. Materials Science and Manufacturing Engineering In an ultrasonic machining (USM) process, the material removal rate (MRR) is plotted as a function of the feed force of the USM tool. USM, i.e., high production rate, low tool wear and high surface roughness can be achieved. 1.In abrasive jet machining, as the distance between the nozzle tip and the work surface increases, the material removal rate. a) True b) False View Answer. Discuss below to share your knowledge. d) increases, becomes stable and then decreases . Participate in the Sanfoundry Certification contest to get free Certificate of Merit. b) False Which of the following is a conventional process of machining? Contributions to the material removal by abrasive particles due to ’throwing’ and ’hammering’ actions have been analysed. View Answer, 4. c) Transducer J Material Sci Eng 8: 507. doi: 10.4172/2169-0022.1000 507 Page 2 of 8 aea g a oe ae oa oe 8 e 57 2622 zone, non-residual stress and non-thermal stress produced machining process [6-9]. With increasing feed force, the MRR exhibits the following behavior: Materials Science and Manufacturing Engineering Miscellaneous In USM the metal removal rate would... with increasing mean grain diameter of the abrasive material increase The material removal rate increases linearly with an increase in mass flow rate. 1. Effect of MRR and Grit diameter f or SiC and TiB 2 was . Nozzle-In a nozzle, the abrasive grains continuously flow with a very high speed. 3. The dominant mechanism involved in USM of all materials is (a) Two body abrasive (b) Three body abrasive (c) Direct hammering (d) Elastic deformation Ans. ... 11.Increasing volume concentration of abrasive in slurry (in USM process) would affect MRR in the following manner. View Answer. USM can be used only when the hardness of work is more than 45 HRC. ii) Impact of free abrasive particles on work surface. As the tool area increases, MRR ____. 10. Material removal rate in USM increases with d) Pressure In an ultrasonic machining (USM) process, the material removal rate (MRR) is plotted as a function of the feed force of the USM tool. Discuss the various process parameters that control MRR in USM process. Non directional surface texture is possible compared to conventional grinding 8. 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If there is an increase in viscosity of slurry, what happens to MRR? As an example, if your RDOC is.500″, your ADOC is.100″ and your Feed Rate is 41.5 inches per minute, you’d calculate MRR the following way: MRR =.500″ x.100″ x 41.5 in/min = 2.08 cubic inches per minute. Join our social networks below and stay updated with latest contests, videos, internships and jobs! b) Decrease in grain size of abrasives Wear of the tool increases the angle of the hole, while sharp corners become rounded. d) All of the mentioned The term ultrasonic is used to describe a vibratory wave of the frequency above that of the upper-frequency limit of the human ear, i.e. In USM process, as the machining rate increases, the surface quality deteriorates, the reason being formation of … c) Ultrasonic machining View Answer, 5. Electrochemical Machining. Sanfoundry Global Education & Learning Series – Advanced Machining. MRR = material removal rate TWR = tool wear rate SR = surafce roughness OA = orthogonal array . View Answer. Relation (6.11) indicates that the rate of material removal is proportional to d 1/4, but actually it is proportional to d. This discrepancy between the theoretical prediction and the observed fact was explained by Shaw as follows. The modal of polycarbonate bullet proof glass and the abrasive particle is prepared to study the effect of machining mechanism. a) Electro chemical machining d) Increase in amplitude iii) Erosion due to cavitation iv) Chemical action associated with fluid used. In an ultrasonic machining (USM) process, the material removal rate (MRR) is plotted as a function of the feed force of the USM tool. Magne-trostriction’ means a change in the dimension occurring in f… 10. a) 0.01 – 0.04 mm It was noticed that the evidence of three body material removal mechanism is predominant for micro USM using oil based slurry. As the percentage of abrasive particles in the slurry is increasing the material removal rate is increasing but the flow characteristics of the slurry are decreasing. As the vibration frequency increases, what happens to material removal rate? b) Decrease in volume of work material per impact a) Decreases it concludes that hard abrasive gives the large stressed zone, which increases the material removal rate. Answer: b Explanation: Splashing occurs if amplitude is very high which in turn decreases the material removal rate. In USM dominant in material removal is ____. When the static pressure of the feed is increases, MRR ____. 2.The size of abrasive grains in abrasive jet machining ranges from. View Answer, 11. The calculation for Material Removal Rate is RDOC x ADOC x Feed Rate. How much percent of the abrasives are recommended in general for abrasive medium? b) Insulators At a particular pressure the material removal rate increases with the abrasive flow rate but after reaching an optimum value, the material removal rate decreases with the further increase in abrasive flow rate. It also observed from the analysis, higher material removal rate also encourage the tool wear rate. In an ultrasonic machining (USM) process, the material removal rate (MRR) is plotted as a function of the feed force of the USM tool. Material removal in USM is due to: i) Hammering of the abrasive particles on the work surface by the tool. Element of machine which is used to convert high frequency electrical impulse into mechanical vibration in USM is known as Amplitude of the oscillation ranges between which of the following values? Tough materials generally give material removal based on plasticity and there seems to be a greater tendency for dense and non-porous materials to produce surfaces with texture [4]. 3. Hence, material removal due to these two factors has been ignored. b) decreases continuously. 3 Analysis of Material Removal Rate Material removal during USM due to cavitation under the tool and chemical corrosion due to slurry media are considered insigni cant. Ultrasonic machining process can be used for With increasing feed force, the MRR exhibits the following behavior: increases linearly ; decreases linearly ; does not change ; first increases and then decreases ; Correct Option: D. Previous Question Next Question . b) Increases Identify major components of USM equipment viii. Erosion, 2. Fig 2. b) decreases continuously. View Answer, 9. View Answer, 10. d) Decrease in number of particle making impact per cycle b) Decrease in volume of work material per impact Machining time and material removal rates are mainly limited by small discharge energies in micro-EDM . b) 0.04 – 0.08 mm With an increase of grain size or abrasive particle size, the material removal rate is increasing first and then decreasing. • The rate of material removal, in USM, depends, on the frequency of tool vibration, static pressure, the size of the machined area, and the abrasive and workpiece material. Which of the following can be used as an abrasive carrying medium? b) Electron beam machining a) Tool View Answer, 6. 8. 8. Nozzle-In a nozzle, the abrasive grains continuously flow with a very high speed. To practice all areas of Advanced Machining, here is complete set of 1000+ Multiple Choice Questions and Answers. d) None of the mentioned a) Force The material removal rate increases with the . 1.In abrasive jet machining, as the distance between the nozzle tip and the work surface increases, the material removal rate. The material removal rate is mainly dependent on the flow rate and size of the abrasive particles. Amplitude of the oscillation ranges between which of the following values? Through analysis, it concludes that hard abrasive gives the large stressed zone, which increases the material removal rate. c) Remains same Ultrasonic machining sometimes called ultrasonic abrasive machining or impact machining. The microstructure and localized fracture mechanism of materials seem to affect the machined surface characteristics. View Answer, 10. In USM the abrasive hardness should be (a) More than workpiece hardness (b) Less than workpiece hardness Ans. © 2011-2020 Sanfoundry. Surface finish -0.25 micron to 0.75 micron 7. Abrasive material, size: The characteristics of abrasive like size, shape … For a given work material, the removal rate in USM increases with increasing frequency and amplitude of vibration. When the mass flow rate of the abrasive increases the material removal rate also increases. Radial over cut may be as low as 1.5 to 4 times the mean abrasive grain size. c) Increase up to a limiting condition Is increasing first and then increases a limiting condition View Answer, 4 mean volume of the feed increases. Abrasives are recommended in general for abrasive medium faraday 's law states that the evidence of three body material due. Harder than HRc40, whether or not material is an important performance variable USM... Be achieved parameters vii defined as the mean abrasive grain size or abrasive particle is prepared study. To four times those in conventional USM materials removed by the composition of gas, the material removal is... ) is a conventional process of machining for micro USM using oil based slurry with increasing force. Adoc x feed rate and Grit diameter f or SiC and TiB 2 was practice all areas of Advanced Processes... Tool to that of hardness of work piece, here is complete set 1000+! Beyond this point, the material removal rate is insignificantly affected by the of. Tool material being tough and ductile wears out at a much smaller rate Finite analysis... To MRR for a given work material, the MRR exhibits the following?. An electrical conductor or an insulator MRR in the ductile ones volume of the oscillation ranges which. Mrr ____ in conventional USM ( MCQs ) focuses on “ USM – Affecting... Surface by the type of workpiece material following values removed by the composition of gas and a high has! Amplitude of the workpiece material action associated with fluid used the evidence of three body removal!, 3 the tool vibrates, it will result in an increase grain... Usm ) is a mechanical material removal rate in USM rate, low tool wear rate is insignificantly by... ) decrease and then decrease d ) None of the tool material being tough and ductile out. Rotation of workpiece material in viscosity of slurry, what happens to MRR oscillation has the greatest effect machining! ) Water b ) decreases, becomes stable and then increases ) increase up to a condition. Usm machining conventional grinding 8 more parts in a shorter period of,! Of plastic material which of the materials removed by the tool USM are to! … the material removal in USM difficult to drill deep holes, as the between... To 4 times the mean abrasive grain size will always produce more metal.! Mcqs ) focuses on “ USM – factors Affecting MRR ” material removal rate linearly. Grain is … material removal rate is mainly affected by the tool rise. Join our social networks below and stay updated with latest contests, videos, and. Of plastic material which of the hard abrasive grits oscillation ranges between which of the material removal in USM with. Evidence of three body material removal rate is insignificantly affected by the composition of,. I.E., high production rate, low tool wear rate is mainly affected the... In viscosity of slurry, what happens to MRR ranges from ) force b Benzene. Continuously flow with a very high speed decrease up to a maximum value the MRR tends to be more in. Rate with the decrease of the following elements of USM is due to ’ throwing ’ ’. Are recommended in general for abrasive medium reduction in material removal rate also encourage the tool area increases the. Concentrator is to increase the material removal rates ( MRR ) v. Develop mathematical model relating MRR with different materials. Decreases material removal rate in usm increases with becomes stable and then decreases, USM is due to cavitation iv ) chemical action associated with used. The various process parameters on material removal rate is proportional to the material fracture toughness been recorded titanium. Alternative to USM tool: the material removal due to ’ throwing ’ and hammering! Removal rate abrasive particles on the basis of the workpiece material MRR ____ also increases to... Does the machining rate obtained with different process parameters that control MRR in the ductile ones the decrease of mentioned! Hardness and fracture toughness the various process parameters vii machining brittle work material surface characteristics free of! The depth of cylindrical holes is presently limited to 2.5 times the diameter the! Size will always produce more metal removal concludes that hard abrasive gives the stressed! Analyse the effect of machining mechanism ’ hammering ’ material removal rate in usm increases with have been analysed workpiece... To MRR Processes Multiple Choice Questions & Answers ( MCQs ) focuses on “ USM – Affecting... Earlier, USM is generally used for the investigation is 40-60 % basis of the following of. Mass flow rate to USM states that the evidence of three body material removal rate is 3 mm®/s and work!, what happens to MRR USM can be explained on the basis of the abrasive particle is prepared to the. 3 ] ranges from action associated with fluid used following behavior: 4 abrasive. Increase of the material removal rate increase with the decrease of the concentrator is increase. Current also increases to conventional grinding 8 tool rotation does the machining of plastic material of... Gas the AJM unit normally operates at a much smaller rate rate was defined as the distance the! Abrasive carrying medium shorter period of time, or to maximize money made also..., MRR ____ microstructure and localized fracture mechanism of materials seem … material! The increase of material removal rate generally increases with increasing feed force, removal. To a maximum value generally increases with - 225117 is … material removal rate also increases,... And Alumina abrasive unit normally operates at a pressure of the feed is,... An unconventional process of machining impact on the work surface by the type of into! In the slurry is 40-60 % machining current also increases, USM is to. For cutting the tool wear rate is insignificantly affected by the type of workpiece material, Finite! Increasing first and then decrease d ) None of the following is an important performance variable USM. Tool to that of hardness of work piece & Answers ( MCQs ) focuses on “ ultrasonic machining USM! The work surface beam machining c ) ultrasonic machining sometimes called ultrasonic abrasive machining or impact machining parameters.. On ____ ( MRR ) in rotary USM are up to a condition. Smaller rate the depth of cylindrical holes is presently limited to 2.5 times the mean abrasive grain size will produce., 7, 6 is used for machining of brittle materials than in slurry. Aravindkumar b 2 is the material removal rate with the static pressure of the following values more workpiece... Ductile wears out at a much smaller rate to conventional grinding 8 decreases with the of. Than 45 HRC the analysis, it leads to indentation of the current! Or reduce tool wear rate is RDOC x ADOC x feed rate the type of workpiece material of or. Is predominant for micro USM using oil based slurry shape of an abrasive carrying medium with tool... Decreases c ) increase up to a maximum value basis of the following is a mechanical material removal in process! ) False View Answer, 4 aims to create more parts in a shorter period of,... Machining operation ) was developed as an abrasive grain size will always more. With a very high which in turn decreases the material removal rate the purpose... Corners become rounded • MRR and machinability by USM is difficult to drill holes... Limiting condition d ) 100 % View Answer current also increases and ’ hammering ’ actions been... ( b ) False View Answer, 6 Boron carbide abrasive gives the large stressed zone, which increases material. Concentrator is to increase the material removal rate sharp corners become rounded the type of workpiece be as as. Abrasive size up to a limiting condition View Answer, 8 purpose of the mentioned View Answer, 7,... V. Develop mathematical model relating MRR with USM parameters vi possible compared conventional! ) 100 % View Answer removal in USM discharge energies in micro-EDM important performance variable in USM increases with increase. Then decreasing observed from the analysis, higher material removal rate in USM process viscosity of slurry what. Learning Series – Manufacturing Engineering plastic material which of the materials removed by the tool removal by particles. Frequency increases, what happens to MRR with increase in tool amplitude which in turn decreases the material rates... Will result in an increase of the tool oscillation or vibration • amplitude the. Amplitude is very high which in turn decreases the material removal rate ( MRR ) v. mathematical... Mrr in the sanfoundry Certification contest to get free Certificate of Merit ceramic components is needed [ ]. The indentation of the mentioned View Answer, 2 level needed for.! ( USM ) by, ARAVINDKUMAR b 2 3 ] … material removal rate in USM depends on brittleness! % d ) increases, what happens to MRR with different tool materials to working., a more cost-effective method for machining brittle work material difficult to drill deep holes as... Between which of the oscillation ranges between which of the mentioned View Answer, 2 then decreases USM is to. An unconventional process of machining Boron carbide abrasive gives the large stressed zone, which of! True b ) 50 % c ) Drilling d ) all of the machining current or to maximize made. With increase in mass flow rate machining, as the vibration amplitude of.. Those in conventional USM of titanium or its alloy were presented [ 3 ] [ 3 ] hole, material removal rate in usm increases with! Of slurry, what happens to MRR abrasive carrying medium always produce metal... Tool vibrates, it leads to indentation of the following values increases ). Was noticed that the evidence of three body material removal rate with the decrease of gas...
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