MANUFACTUARING TECHNOLOGY - 1

UNIT-3
METAL FORMING PROCESSES
2 Marks
1.List out the types of forging machines?[au may 05]
Cold working processes

Drawing Squeezing Bending

*Blank drawing * Coining * Plate bending

*Wire drawing * Sizing *Roll forming
*Tube drawing *Swaging * Angel bending
*Metal spinning *Knurling * Seaming
*Embossing * Extrusion

2.Define cold working of metals?

The processes which are working below the recrystallization temperature
are called cold processes.
3.Give some examples for mechanical working of metals?
* Rolling * Forging *Extrusion *Drawing *Press
working
4.Define hot working of metals?
The processes which are working above the recrystallization
temperature are called hot working of metals.
5.What are the advantage of hard working over cold working?
Hot working requires less force to get necessary deformation.
Brittle materials can also be hot worked.
6.Name two metals having re-crystallization temperature below room
temperature?
Lead
Tin.
7.What is meant by re-crystallization temperature?[A.U. apr 10]
The approximate minimum temperature at which complete
recrystallization of cold worked metals takes place with in a specified time
is known as re-crystallization.
8.Distinguish between hot working and cold working of metal?[A.U. apr
12, nov 13]
Hot working Cold working
Working above recrystallization Below recrystallization
temperature. temperature.
New crystals are formed after hot No recrystallization .
working.
It hardens the metal. No hardening.
Impurities are removed from the Impurities are not removed.
metal.
9.What are the types of rolling mills?[A.U. may 05]
Two high rolling mill
Three high rolling mill
Four high rolling mill
Multi high rolling mill
Universal high rolling mill
10.Define forging?
The mechanical working of metals by which metals and alloys are plastically
deformed by the application of compressive force is known as forging process.
11.What is meant by fullering?[A.U. apr 13]is
Reducing the stock and increasing the length of the work piece by
applying pressure on it is known as fillering.
12.What is upset forging?[A.U. nov 09]
It is used to form the head of bolt and rivet or pins. The head may be
square hexagonal or hemispherical. The machine is having a die set. The die
set consists of a fixed die and movable punch. The heated metal bar is held
inside the solid die and the force is given to the punch. So, the punch will
squeeze the heated metal to the shape of the die gravity.
13.What is meant by closed die forging?[A.U. nov 10]
In the closed die forging, the impressions are cut in the die block and the
metal is forced to get the final shape.
14. Define upsetting?
Upsetting is a process of increasing the thickness of a bar at the expense
of its length.
15. What are the disadvantage of forging process?[A.U. nov 09]
Precise tolerances are less.
It is possible warping of the material during the cooling process.
Metal grain structure varies.
It is possible reaction between the surrounding atmosphere and the
metals.
The metals is less ductile.
Residual stress may occur.
Heavier and more powerful equipment is needed.
Stronger tooling is required.
16. Define extrusion process?[A.U. apr 10,12]
The heated metal is compressed and forced through a suitable shaped die.
The force requirement for the cold extrusion process is high. So, most of the
metals are extruded in hot conditions only.
17.Differentiate extrusion and forging?[A.U. nov 13]
Extrusion Forging
The heated metals is compressed The heated metal bar is held
and forced through a suitable inside the solid die and the force
shaped die.. is given to the punch. So, the
punch will squeeze the heated
metal to the shape of the die
cavity.
Most of the metals are extruded Both hot and cold conditions are
in hot conditions only. preferred
Mainly rollers are used to extrude Either hammer or press tool is
the object used to apply the pressure.

18.Define the term extrusion ratio?[A.U. nov 11]

It is defined as the ratio of the cross sectional area of the billet to the
cross section area of the product.
 19.Classify the types of extrusion?[A.U. may 06]
Extrusion

Hot extrusion Cold extrusion

(or) impact extrusion

Forward (or) backward (or)

direct extrusion indirect extrusion
20. List two advantages of cold extrusion over hot extrusion?[A.U. nov
12]
Good surface finish.
Better dimensional accuracy.
21.Distinguish between wire drawing and tube drawing with sketches?
[A.U. nov 09]
Wire drawing Tube drawing
It is the process used to reduce the It is the process to size tube by
diameter of a wire by pulling the shrinking a large diameter tube
wire through a single, or serious into a smaller one, by drawing the
of drawing dies. tube through a die.
The process is carried out at the The process is carried out at room
elevated temperature for large temperature for both large and
wires to reduce forces. small scale production.
Mandrels are not used. Mandrels are used.
It is a slow process. It is faster than wire drawing.

22.Explain isothermal forging?

In the process, both the dies and forging stock are kept at the same
forging temperature.

23.Define powder forging?

It is also called powder metal forging combine with conventional forging.
It has an advantage of 100% utilization and density of the material increases
almost 100%.

24.Explain orbital forging?

 In this method, the upper die of the work piece is concentrated on small
area of the work piece only.
25.Mention the different types of shape rolling operation?[A.U. nov 10]
Ring rolling,
Thread rolling.

26.List out any four parts that can be manufactured by shape rolling
operations?[A.U. apr 10]
Straight and long structural shapes,
Solid bars,
I beams,
Channels ,
Railroad rails.

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