Deck 15: Bulk Deformation Processes in Metal Workiing

Question 1

Which of the following are basic bulk deformation processes in metal forming (three correct answers):

A)bar drawing
B)blanking
C)deep drawing
D)extrusion
E)forging
F)stamping

Answer 1

bar drawing
extrusion
forging

Question 2

Rolling is a bulk deformation process in which the thickness of the work is reduced by compressive forces exerted by two opposing rolls:

Answer 2

True

Question 3

The starting workpiece in hot rolling of steel plate and sheet stock is which one of the following:

A)bar stock
B)billet
C)bloom
D)slab
E)wire stock

Answer 3

slab

Question 4

Furnaces used to heat cast steel ingots to achieve a uniform temperature throughout prior to rolling are called which of the following (one best answer):

A)annealing furnaces
B)heat treating ovens
C)soaking pits
D)tempering furnaces

Question 5

The maximum possible draft in a rolling operation depends on which of the following parameters (two correct answers):

A)coefficient of friction between roll and work
B)roll diameter
C)roll velocity
D)stock thickness
E)strain
F)strength coefficient of the work metal

Question 6

Which of the following stress or strength parameters is used in the computation of rolling force (one best answer):

A)average flow stress
B)compression strength
C)final flow stress
D)tensile strength
E)yield strength

Question 7

Which of the following rolling mill types are associated with relatively small diameter rolls in contact with the work (two correct answers):

A)cluster mill
B)continuous rolling mill
C)four high mill
D)reversing mill
E)three high configuration

Question 8

Production of pipes and tubes is associated with which of the following bulk deformation processes (three correct answers):

A)extrusion
B)hobbing
C)ring rolling
D)roll forging
E)roll piercing
F)tube sinking
G)upsetting

Question 9

Which of the following stress or strength parameters is used in the computation of the maximum force in a forging operation (one best answer):

A)average flow stress
B)compression strength
C)final flow stress
D)tensile strength
E)yield strength

Question 10

Which of the following operations are closely related to open-die forging (three best answers):

A)cogging
B)flashless forging
C)fullering
D)impression-die forging
E)Mannesmann process
F)precision forging
G)upsetting

Question 11

Flash in impression die forging serves no useful purpose and is undesirable because it must be trimmed from the part after forming:

Question 12

Which of the following are classified as forging operations (four correct answers):

A)coining
B)fullering
C)impact extrusion
D)roll piercing
E)swaging
F)thread rolling
G)trimming
H)upsetting

Question 13

Which of the following are alternative names for indirect extrusion (two correct answers):

A)backward extrusion
B)direct extrusion
C)forward extrusion
D)impact extrusion
E)reverse extrusion

Question 14

Production of tubing is possible in indirect extrusion but not in direct extrusion:

Question 15

In metal extrusion, the extrusion ratio is also known by which of the following terms (one best answer):

A)area reduction
B)draft
C)reduction
D)reduction ratio

Question 16

Which of the following stress or strength parameters is used in the computation of the force in an extrusion operation (one best answer):

A)average flow stress
B)compression strength
C)final flow stress
D)tensile strength
E)yield strength

Question 17

In which of the following extrusion operations is friction a factor in determining the extrusion force:

A)direct extrusion
B)indirect extrusion

Question 18

Theoretically, the maximum reduction possible in a wire drawing operation, under the assumptions of a perfectly plastic metal, no friction, and no redundant work, is which one of the following:

A)zero
B)0.63
C)1.0
D)2.72

Question 19

Which of the following bulk deformation processes are involved in the production of nails for lumber construction (three best answers):

A)bar and wire drawing
B)extrusion
C)flashless forging
D)impression die forging
E)rolling
F)upsetting

Question 20

Johnson's formula is associated with which one of the four bulk deformation processes:

A)bar and wire drawing
B)extrusion
C)forging
D)rolling