Metal Forming

Question 1

what is bulk deformation?

Answer 1

metal changes shape/dimensions but not volume

Question 2

what state is the metal in in bulk metal formation?

Answer 2

molten red hot metal

Question 3

examples of bulk metal formation

Answer 3

• forging
• rolling
• extrusion

Question 4

describe the extrusion process ?

Answer 4

Extrusion is a bulk forming process in which the work metal is forced or compressed to flow through a die hole to produce a desired cross-sectional shape.

Question 5

applications of extrusion?

Answer 5

tubes, hollow pipes, frames, doors and window profile

Question 6

describe forging?

Answer 6

It is a bulk deformation process in which the work piece is compressed between two dies using impact loading to plastically deform it.

Question 7

advantages of forging

Answer 7

• stronger than machined products
• because of the grain flow products are durable and withstand heavy loads

Question 8

describe open die forging?

Answer 8

It is a bulk deformation process in which the work piece is compressed between two dies using impact loading to plastically deform it.

Question 9

describe closed die forging?

Answer 9

It is a bulk deformation process in which the work piece is compressed between two dies using impact loading to plastically deform it.

Question 10

aplications of open die?

Answer 10

rotors

Question 11

aplications of closed die?

Answer 11

• knives
• crankshaft
• bolts
• gears
• hand tools

Question 12

rolling types?

Answer 12

• flat rolling
• shape rolling
• thread rolling

Question 13

flat rolling?

Answer 13

Flat rolling is a metal forming process in which the thickness of the workpiece is reduced by compressive forces exerted by two rolls rotating in opposite direction. This is usually used to obtain sheet metals at the desired thickness to be used in further operations.

Question 14

shape rolling?

Answer 14

opposing rolls to change shape of metal

Question 15

thread rolling?

Answer 15

making screw shapes

Question 16

shearing?

Answer 16

upper and lower blades used to cut the metal and between them is the clearance they are called the punch and die

Question 17

how do we determine clearance size?

Answer 17

hard metals require big clearance while soft metals require small clearance

Question 18

what are plastic and elastic zones?

Answer 18

metal recovers after load in elastic zones but is permanantly deformed in plastic zone

Question 19

blanking?

Answer 19

Blanking is a cutting process in which a large piece of sheet metal is removed from a larger piece of stock by applying a great enough shearing force. In this process, the piece removed, called the blank, is the desired part.

Question 20

punching?

Answer 20

is a cutting process in which small material is removed from a piece of sheet metal by applying a great enough shearing force. The product is the sheet metal and the removed part is scrap.

Question 21

what is the spring back effect in bending and how to mitigate its effect?

Answer 21

after being bent the metal returns back a certain distance because of its spring back component. this can be mitigated by increasing the bending angle

Question 22

what is a problem with bending?

Answer 22

grain flow must be perpindicular. this is solved by bending at a perpendicular angle to the metal

Question 23

what are the types of v-bending?

Answer 23

• air bending
• bottoming

Question 24

circular roller bending?

Answer 24

A sub-operation of bending called Circular Roll Bending where the sheet metal is passed between 3 Rolls to produce a cylinder.

Question 25

embossing?

Answer 25