Electrochemical Machining (ECM): Principles and Applications in Complex Geometries

Question 1

In ECM, the material removal from the workpiece is achieved through which electrochemical reaction?

Accepted Answer

Anodic dissolution

Answer

Electroplating

Answer

Cathodic protection

Answer

Electropolishing

Question 2

Which of the following is NOT an advantage of ECM?

Accepted Answer

Low capital investment

Answer

Minimized thermal distortion

Answer

Ability to machine intricate shapes

Answer

Reduced tooling costs

Question 3

In ECM, the electrolyte used is typically:

Accepted Answer

Aqueous solution of sodium chloride

Answer

Liquid nitrogen

Answer

Molten salt

Answer

Pure water

Question 4

In ECM, the optimal gap between the tool electrode and the workpiece is typically maintained within the range of:

Accepted Answer

0.1 - 0.5 mm

Answer

0.5 - 1.0 mm

Answer

Over 2.0 mm

Answer

1.0 - 2.0 mm

Question 5

ECM can be employed to machine:

Accepted Answer

Both external and internal surfaces

Answer

Only flat surfaces

Answer

Only internal surfaces

Answer

Only external surfaces

Question 6

What is the primary mechanism of material removal in Electrochemical Machining (ECM)?

Accepted Answer

Anodic dissolution

Answer

Thermal melting

Answer

Chemical etching

Answer

Mechanical abrasion

Question 7

Which of the following materials is MOST suitable for machining using ECM?

Accepted Answer

High-strength alloys

Answer

Polymers

Answer

Ceramics

Answer

Composites

Question 8

In ECM, what is the role of the electrolyte solution?

Accepted Answer

Conducts electricity and removes reaction products

Answer

Acts as a coolant to dissipate heat

Answer

Increases the hardness of the tool electrode

Answer

Provides mechanical support to the workpiece

Question 9

Which of the following is a significant advantage of ECM over conventional machining?

Accepted Answer

No tool wear

Answer

High material removal rate

Answer

Ability to machine any material

Answer

Low capital cost

Question 10

What type of current is typically used in Electrochemical Machining (ECM)?

Accepted Answer

Direct current (DC)

Answer

Alternating current (AC)

Answer

High-frequency alternating current (HFAC)

Answer

Pulsed direct current (PDC)

Question 11

Which of the following factors significantly influences the material removal rate in ECM?

Accepted Answer

Current density

Answer

Cutting speed

Answer

Tool material

Answer

Ambient temperature

Question 12

What is a major limitation of Electrochemical Machining (ECM)?

Accepted Answer

Difficulty in machining sharp corners

Answer

High energy consumption

Answer

Inability to machine conductive materials

Answer

Generation of hazardous waste

Question 13

Which industry widely utilizes ECM for manufacturing turbine blades?

Accepted Answer

Aerospace

Answer

Electronics

Answer

Automotive

Answer

Construction

Question 14

In ECM, the gap between the tool electrode and the workpiece is typically in the range of:

Accepted Answer

0.1 mm to 0.5 mm

Answer

50 mm to 100 mm

Answer

10 mm to 50 mm

Answer

1 mm to 5 mm

Question 15

What is the purpose of using a passivation layer on the tool electrode in ECM?

Accepted Answer

Prevent unwanted machining of the tool

Answer

Increase the electrolyte flow rate

Answer

Improve electrical conductivity

Answer

Reduce the surface roughness of the workpiece

Question 16

In Electrochemical Machining (ECM), the material removal rate is primarily influenced by which factor?

Accepted Answer

Current density

Answer

Tool feed rate

Answer

Electrolyte temperature

Answer

Workpiece material hardness

Question 17

Which of the following materials is NOT suitable for Electrochemical Machining (ECM)?

Accepted Answer

Ceramics

Answer

Titanium

Answer

Stainless steel

Question 18

The electrolyte used in ECM serves primarily as a:

Accepted Answer

Conductor for electric current

Answer

Cooling agent for the workpiece

Answer

Protective layer against corrosion

Answer

Lubricant for the tool

Question 19

What is the primary advantage of Electrochemical Machining (ECM) over traditional machining methods?

Accepted Answer

Ability to machine complex geometries and hard-to-cut materials

Answer

Higher material removal rate

Answer

Lower tooling cost

Question 20

Which of the following is NOT a characteristic of the surface finish produced by Electrochemical Machining (ECM)?

Accepted Answer

High surface roughness

Answer

No burrs or tool marks

Answer

Minimal heat affected zone

Answer

Uniform surface finish

Question 21

The gap between the tool and the workpiece in ECM is typically maintained at:

Accepted Answer

0.05 to 0.5 mm

Answer

1 to 5 mm

Answer

10 to 50 mm

Answer

More than 50 mm

Question 22

Which of these factors does NOT affect the accuracy of Electrochemical Machining (ECM)?

Accepted Answer

Electrolyte viscosity

Answer

Electrolyte flow rate

Answer

Workpiece material composition

Answer

Tool shape and dimensions

Question 23

Electrochemical Machining (ECM) is commonly used in the manufacturing of which of the following products?

Accepted Answer

Turbine blades

Answer

Plastic injection molds

Answer

Car engine pistons

Answer

Cutting tools

Question 24

In ECM, the tool acts as the:

Accepted Answer

Cathode

Answer

Insulator

Answer

Electrolyte

Answer

Anode

Question 25

A major limitation of Electrochemical Machining (ECM) is:

Accepted Answer

High tooling costs

Answer

Limited material removal rate

Answer

Inability to machine complex shapes

Answer

Low surface finish quality