Bulk Metal Forming

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, or (e) yield strength?

(a) average flow stress

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, or (e) yield strength?

(a) average flow stress

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, and (e) reverse extrusion?

(a) backward (e) reverse extrusion?

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, and (f) upsetting?

(a) bar and wire drawing (c) flashless forging, (d) impression-die forging

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, and (e) three-high configuration?

(a) cluster mill (c) four-high mill

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, and (f) strength coefficient of the work metal?

(a) coefficient of friction between roll and work (b) roll diameter

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) soaking, and (h) upsetting?

(a) cogging (c) fullering (h) upsetting

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, and (h) upsetting?

(a) coining (b) fullering (e) swaging (h) upsetting

In which of the following extrusion operations is friction a factor in determining the extrusion force (one best answer): (a) direct extrusion or (b) indirect extrusion?

(a) direct extrusion

Production of pipes and tubes is associated with which of the following bulk deformation processes (two correct answers): (a) extrusion, (b) hobbing, (c) ring rolling, (d) roll forging, (e) roll piercing, (f) tube sinking, and (g) upsetting?

(a) extrusion (f) tube sinking

Which of the following are advantages and characteristics of hot working relative to cold working (four correct answers): (a) fracture of workpart is less likely, (b) friction is reduced, (c) increased strength properties, (d) isotropic mechanical properties, (e) less overall energy is required, (f) lower deformation forces is required, (g) more significant shape changes are possible, and (h) strain-rate sensitivity is reduced?

(a) fracture of work part is less likely (d) isotropic mechanical properties (f) lower deformation forces is required (g) more significant shape

Flash in impression-die forging serves no useful purpose and is undesirable because it must be trimmed from the part after forming: (a) true or (b) false?

(a) true

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 of the following (one answer): (a) zero, (b) 0.63, (c) 1.0, or (d) 2.72?

(b) 0.63

Johnson's formula is associated with which one of the four bulk deformation processes: (a) bar and wire drawing, (b) extrusion, (c) forging, and (d) rolling?

(b) extrusion

The production of tubing is possible in indirect extrusion but not in direct extrusion: (a) true or (b) false?

(b) false

The coefficient of friction between the part and the tool in cold working tends to be (a) higher, (b) lower, or (c) no different relative to its value in hot working?

(b) lower

The flow curve expresses the behavior of a metal in which of the following regions of the stress- strain curve: (a) elastic region or (b) plastic region?

(b) plastic region

Which of the following are bulk deformation processes (three correct answers): (a) bending, (b) deep drawing, (c) extrusion, (d) forging, (e) rolling, and (f) shearing?

(c) extrusion (d) forging (e) rolling

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, or (e) yield strength?

(c) final flow stress

Increasing strain rate tends to have which one of the following effects on flow stress during hot forming of metal: (a) decreases flow stress, (b) has no effect, or (c) increases flow stress?

(c) increases flow stress

Hot working of metals refers to which one of the following temperature regions relative to the melting point of the given metal on an absolute temperature scale: (a) room = temperature, (b) 0.2Tm, (c) 0.4Tm, or (d) 0.6Tm?

(d) 0.6Tm

The average flow stress is the flow stress multiplied by which of the following factors: (a) n, (b) (1 + n), (c) 1/n, or (d) 1/(1 + n), where n is the strain hardening exponent?

(d) 1/(1 + n)

The starting work piece in steel hot rolling of plate and sheet stock is which of the following (one best answer): (a) bar stock, (b) billet, (c) bloom, (d) slab, or (e) wire stock?

(d) slab