Lectures 3-4 Processes

Question 1

Out of Sand, Investment and Die casting

Cost

Answer 1

L H H

Question 2

Out of Sand, Investment and Die casting

Rate

Answer 2

M L H

Question 3

Out of Sand, Investment and Die casting

Quality

Answer 3

L H M

Question 4

Out of Sand, Investment and Die casting

Flexibility

Answer 4

M M L

Question 5

Bulk deformation results in a massive — —- and used to work parts which have a high —- to —– ratio.

Answer 5

shape change, surface area, volume

Question 6

Rolling is a process where the workpiece is

Answer 6

compressed between two rollers

Question 7

Forging is a process where the workpiece is

Answer 7

compressed between two dies

Question 8

Extrusion is a process by which the workpiece is

Answer 8

compressed or pushed into a die opening to take the shape of the cross-section

Question 9

Wire or rod drawing is a process by which the workpiece is

Answer 9

pulled through a die opening

Question 10

Sheet metal forming is usually called

Answer 10

pressworking

Question 11

Bending is carried out by

Answer 11

using a punch in the shape of the bend desired

Question 12

Deep/cup drawing is carried out in a similar method to

Answer 12

bending but is clamped on either side

Question 13

Shearing is a process using a great enough

Answer 13

force to cause the metal to fail, like cutting it with scissors

Question 14

Cold working is usually carried out —- the recrystallisation temp

Answer 14

below

Question 15

Hot working is usually carried out —- the recrystallisation temp

Answer 15

above

Question 16

When something is cold worked what occurs in the material?

Answer 16

Work hardening

Question 17

Few pros of cold working

Answer 17

• Good quality surface finish
• Good dimensional accuracy
• No heating required so it is cheaper

Question 18

Few cons of cold working

Answer 18

• Very high forces required
• Equipment is heavy duty and expensive
• Pre-cleaning required
• Tools wear out and need replacement

Question 19

Few Pros for hot working

Answer 19

• Lower forces and power required
• No unnecessary strengthening of part
• Properties of part are usually isotropic
• Large amounts of deformation are more possible

Question 20

Few cons to hot working

Answer 20

• Lower accuracy
• Higher total energy
• Poor surface condition
• Shorter tool life

Question 21

An ingot can be rolled into what?

Answer 21

bloom, slab

Question 22

A bloom can be rolled into what?

Answer 22

slab, billet

Question 23

Difference between a forge hammer and forge press

Answer 23

Hammer applies an impact load,
press applis a gradual load

Question 24

Barelling or pancaking is the result of which process

Answer 24

open die forging

Question 25

Pros to open die forging

Answer 25

• Simple dies
• Wide range of part sizes

Question 26

Cons to open die forging

Answer 26

• Limited to simple shapes
• Machining to final shape necessary

Question 27

Impression die forging is the process by which the workpiece is

Answer 27

pressed between two dies that have the imprints

Question 28

Differences in the grain flow between cast, machined and forged parts

Answer 28

Cast - no grain flow
Machined - broken grain flow
Forged - true grain flow

Question 29

Upset test defines the materials ability to

Answer 29

resist surface cracking when reduced in height

Question 30

Hot twist test defines the materials ability to

Answer 30

turn before failure

Question 31

Precision forging is carried out by

Answer 31

enclosing the workpiece within the upper and lower punches and two dies either side

Question 32

Swaging is the process by which the tubes diameter is reduced

Answer 32

by dragging through a narrowing die

Question 33

Heading/upset forging is the process by which

Answer 33

the end of the wire is widened in CSA to form a head

Question 34

Coining is a process to create

Answer 34

slight indentation onto a metal surface

Question 35

Roll forging is a way to create

Answer 35

grooves and indents into a bar

Question 36

Orbital forging is a process where

Answer 36

the top die with the indent has a circular motion