MODAL QUESTIONS

GROUP 1:

QUESTIONS

Q1) How is tool wear monitored and compensated for in

micromachining operations?
Common monitoring techniques:

✓ Force monitoring: Measuring cutting forces generated during

machining, which increase as the tool wears.
✓ Vibration analysis: Analyzing vibrations produced by the machining
process, as increased wear can cause changes in vibration patterns.
✓ Acoustic emission: Detecting acoustic signals generated by the tool-
workpiece interaction, which can indicate wear progression.
✓ Surface roughness measurement: Monitoring changes in surface finish
as a result of tool wear.
✓ Image processing: In some cases, capturing images of the tool edge to
analyze wear patterns, particularly relevant in micro-EDM.

Compensation methods:

Feed rate adjustment: Reducing the feed rate as tool wear increases to
maintain desired surface quality.
Depth of cut adjustment: Adjusting the cutting depth to compensate for
tool wear.
Tool change scheduling: Based on monitored wear levels, proactively
changing the tool before excessive wear occurs.
Real-time compensation: Utilizing advanced control systems to
continuously adjust machining parameters based on live tool wear data

Q2) What are the limitations of mechanical micromachining

in terms of material compatibility?
 a) Hardness and Brittleness: Materials like glass, ceramics, and monocrystalline silicon
are difficult to machine due to their high hardness and brittleness. This can lead to rapid
tool wear, chipping at the edges, and cracks in the workpiece.
b) Cutting Forces: High cutting forces in relation to the tool's strength properties can cause
damage to both the tool and the workpiece. This is especially problematic for materials
with high hardness and wear resistance.
c) Tool Wear: Rapid wear of cutting edges is a common issue when machining hard and
brittle materials. This can result in poor surface finish and dimensional inaccuracies.
d) Stress Concentration: Excessive stress in the cutting zone can cause various types of
damage, such as chipping and cracks. This is particularly challenging when machining
materials with low fracture toughness.
e) Material Removal Rate: The material removal rate can be significantly lower for hard
and brittle materials, making the process less efficient.
f) Tool Material: The tool material must have properties that exceed those of the
workpiece material. For example, microdrills made of sintered carbides or diamond are
often required for machining hard materials

Q3) How can process parameters be optimized to achieve

high precision and surface finish in micromachining?
1)Cutting Speed

Higher Cutting Speeds: Generally, higher cutting speeds can improve surface finish by
reducing the formation of built-up edges and minimizing tool wear.

2) Feed Rate

Lower Feed Rates: Reducing the feed rate can enhance surface finish by decreasing the cutting
forces and reducing tool deflection.

3)Depth of Cut

Shallow Depth of Cut: Using a shallow depth of cut can help in achieving a smoother surface
finish and reducing tool wear.

4)Tool Material and Coating

Advanced Tool Materials: Utilizing tools made from advanced materials like
diamond or carbide can improve precision and surface finish.

Coated Tools: Applying coatings such as PVD (Physical Vapor Deposition) can enhance tool
life and performance.
5)Coolant and Lubrication

Effective Coolant Application: Proper use of coolants can reduce heat generation and improve
surface finish.

Lubrication: Adequate lubrication can minimize friction and wear, leading to better surface
quality.

6)Vibration Control :Minimizing Vibrations by Implementing strategies to reduce

vibrations, such as using dampers or optimizing machine rigidity, can significantly
improve surface finish.

GROUP 2

Questions
1.
o Explain the key difference between Micro-EDM and Micro-
LBM in terms of energy source and material removal
mechanism."

o Answer:
o Micro-EDM uses electrical sparks (electrical energy) to remove material,
while Micro-LBM uses a focused laser beam (light energy).
o Micro-EDM is suitable for conductive materials, whereas Micro-LBM can
work on almost any material, including non-conductive ones.
2.
Application-Based Question:
o "Why is Micro-EDM preferred for machining conductive
materials, while Micro-LBM is more versatile for non-
conductive materials?"

o Answer:
 o Micro-EDM relies on electrical conductivity to generate sparks, making it
ideal for conductive materials.
o Micro-LBM uses a laser beam, which does not depend on material
conductivity, making it versatile for both conductive and non-conductive
materials.
3.
Critical Thinking Question:
o "What are the limitations of thermal micromachining
processes, and how can they be mitigated in industrial
applications?"

o Answer:
o Limitations:
▪ High equipment cost.
▪ Limited material removal rate compared to conventional machining.
▪ Potential for thermal damage (e.g., heat-affected zones).

Mitigation Strategies:
• Use advanced cooling systems to reduce thermal damage.
• Optimize process parameters (e.g., pulse duration, energy intensity).
• Combine thermal micromachining with other processes for better efficiency

Group 3
Questions
 Q1. What is the purpose of the following terms used in CHM?
a. Etchant: to dissolve a metal by turning it into a metallic salt, this then goes into
solution. Many chemical are available as etchants: FeCl3, Chromic acid, FeNO3,
HF, HNO3.
b. Maskant: Maskants (chemically resistant coatings) are used to cover the
surfaces which are not to be machined – does not allow the etchant to react
reach and react with work piece to dissolve it.

Q2. During electrochemical micro machining of iron with a copper electrode

working in a 5 (N) Nacl solution in water and equilibrium gap of 0.0125 cm has
been achieved at a current density of 150A/cm^2 .if the operating voltage has
been 10V .determine the feed rate .
Sol: Given Data
V=10V ,h=0.0125cm ,F=1609A.min
M 5
we know that 𝐸 = = =2.5
v 2
𝑉𝑀𝑅𝑅 MRR E
thus Feed rate 𝑓 = again =
PHI I FP
VE
𝑓= substituting the values ,the answer is
⍴HF⍴

𝒇 = 𝟎. 𝟎𝟐𝟎𝐜𝐦/𝐬

Q3. a. A cylindrical tool with a diameter of 5 mm is used in an ECMM setup. If the

total current applied is 12 A, calculate the current density at the tool surface.

Sol: Given Data

𝜋𝑑 2 𝜋0.52
I=12A d=5mm=0.5cm 𝐴 = = =0.19625𝑐𝑚2
4 4
 I 12
⍴= ⍴= =61.146 A/𝒄𝒎𝟐
A 0.19625

b. Given that the MRR is influenced by the current and the specific removal rate
(SRR), if the current is 10 A and the SSR is 0.1 mm³/A·min, what is the MRR?
Sol: Given Data

I=10A SSR =0.1𝑚𝑚3 /A.min MRR=I.SSR MRR=10X0.1=1𝒎𝒎𝟑 /min

c. The electrochemical micromachining of an iron surface that is 25mmX25mmin
cross section using Nacl in water as electrolyte .The gap between the tool and the
workpiece is 0.25mm.The supply voltage is 12V DC .The specific resistance of the
electrolyte is 3 ohm cm .Estimate the material removal rate in mm3/min.specific
heat of the electrolyte is given as 0.997cal/goc .The ambient temperature is 35 oc
and the electrolyte boiling temperature is 95 oc, density =7860kg/m3
sol: Given Data
Agap=25mmx25mm h=0.25mm r=3ohm cm Ce=0.99cal/goc Tb=35oc F=96500c/mol
V=12V
IAg V h 0.25
MRR= I= R=r x R=30 x =0.012Ὧ
FVs 𝑅 Agap 25 x 25

12 1000 x 56
Then I= =1000A MRR = =0.29015 mm3/min
0.012 96500 x 2

GROUP 4
Questions
Problem 1: Material Removal Rate (MRR)
In an ECDM process using a sodium hydroxide electrolyte, a voltage of 15 V and
a current of 10 A are applied. The machining time is 2 minutes. The workpiece
material is alumina (Al2O3) with a density of 3.95 g/cm³. Assuming an efficiency
of 80%, calculate the approximate volume of material removed.
Solution:
1. Calculate the total charge (Q) passed: Q = Current (I) × Time (t) = 10 A × 120 s =
1200 Coulombs
2. Calculate the theoretical mass (m) of material removed using Faraday's Law: m
= (Q × M) / (n × F) where:
o M = Molar mass of Al2O3 = 101.96 g/mol
o n = Number of electrons involved in the reaction (assume 6 for Al2O3)
o F = Faraday's constant = 96485 C/mol m = (1200 C × 101.96 g/mol) / (6 ×
96485 C/mol) = 0.211 g
3. Account for efficiency: Actual mass removed = Theoretical mass × Efficiency =
0.211 g × 0.8 = 0.169 g
4. Calculate the volume (V) of material removed: V = Mass / Density = 0.169 g /
3.95 g/cm³ = 0.043 cm³ = 43 mm³

Problem 2: Discharge Energy

An ECDM process uses a pulsed DC power supply with the following parameters:
Voltage (V): 80 V
Current (I): 5 A
Pulse duration (t): 10 µs
Pulse frequency (f): 10 kHz
Calculate the average discharge energy per pulse and the average power
delivered.
Solution:
1. Calculate the energy per pulse (E): E = V × I × t = 80 V × 5 A × 10 × 10⁻⁶ s = 4 ×
10⁻³ J = 4 mJ
2. Calculate the average power (P): P = E × f = 4 × 10⁻³ J × 10 × 10³ Hz = 40 W

Problem 3: Overcut Estimation

During ECDM of a tungsten carbide workpiece, an overcut of 10 µm is observed.
The
tool electrode has a diameter of 100 µm. Estimate the diameter of the machined
hole.
Solution:
Overcut: The overcut is the additional material removal beyond the tool
electrode
dimensions.
Machined Hole Diameter: = Tool Electrode Diameter + 2 × Overcut = 100 µm + 2
× 10 µm = 120 µm
Group 5
Questions
Q1.What are the key working principles of Ultra-Precision Machining (UPM)?
Solution:
Ultra-precision machining (UPM) is a high-precision material removal process
that operates at the nano-meter scale to achieve smooth surfaces and tight
tolerances. Its key working principles include:

1. Minimal Material Removal – Unlike conventional machining, UPM

removes extremely small increments of material to enhance surface
quality.
2. Specialized Tools – Diamond-based cutting tools are commonly used
due to their hardness and ability to produce ultra-smooth finishes.
3. Advanced Control Systems – CNC machines with high-resolution
feedback mechanisms are employed to maintain precise control over
machining movements.
4. Environmental Control – Temperature stability is crucial to prevent
work piece distortion due to thermal expansion.
5. Applications – UPM is widely used in manufacturing optical
components (lenses, mirrors), precision molds, medical implants, and
semiconductor devices.

Q2. Explain the working principles of Electrolytic In- Process

Dressing (ELID) Grinding.
Solution:
Electrolytic In-Process Dressing (ELID) grinding is a technique that uses an
electrolytic reaction to maintain sharpness in a metal-bonded super abrasive
grinding wheel. The working principles include:

1. Electrolytic Dressing – The metallic bond holding the abrasive grains is

gradually dissolved by electrolysis, exposing new, sharp abrasive
 particles.
2. Abrasive Wear and Bond Removal Balance – A balance must be
maintained between the rate of metal bond removal and the wear
rate of the abrasive grains.
3. Influence of Parameters – The removal rate of the metal bond depends
on voltage, current, and the electrode gap, while the wear rate of the
abrasive grains is influenced by grinding force and work piece
properties.
4. Diamond Exposure Mechanism – Electrolytic dissolution is highest at
the diamond-metal interface, progressively exposing fresh diamond
particles for efficient grinding.
5. Types of ELID Grinding – There are different ELID methods, including:
1. ELID-I: Continuous dressing during grinding.
2. ELID-II: Dressing at intervals to reduce tool clogging.
3. ELID-III: Electrode-less dressing for specific applications.

Q3. What are the advantages of ELID grinding compared to

conventional grinding methods?
Solution:
ELID grinding offers several advantages over traditional grinding methods,
including:

1. Superior Surface Finish – Produces high-quality surfaces with

minimal defects.
2. High Surface Accuracy – Achieves precise tolerances, making
it suitable for critical applications.
3. Low Subsurface Damage – Reduces mechanical and thermal damage
to the work piece.
4. Improved Tool Life – Continuous in-process dressing minimizes
tool wear and extends tool lifespan.
5. Reduced Clogging and Glazing – Electrolytic dressing prevents the
accumulation of debris, maintaining effective cutting performance.