Metal Forming Processes

Question 1

What extrusion process will be ideal for producing a component out of a less ductile material?

Answer 1

Hydrostatic extrusion

Question 2

For a drawing operation, if a certain force is required to reduce the cross-sectional area from A0to Af, by how much would you change the force to get 50% of Af instead?

Answer 2

Decrease by 65%

Question 3

Which forging process makes the most accurate and net-shape metal parts?

Answer 3

Flashless closed-die forging

Question 4

Does forging or casting create more residual stresses in a part?

Answer 4

Casting

Question 5

A process whereby workpiece is shaped by compressive forces applied through hammers and various dies

Answer 5

Forging

Question 6

Extrusion

Answer 6

Material is pushed through a die to obtain continuous products with various constant cross-sections

Question 7

Material is pulled through a die to obtain continuous products with various constant cross-sections

Answer 7

Drawing

Question 8

Rolling

Answer 8

A process of reducing the thickness of a long workpiece by compressive forces applied through a set of rolls

Question 9

Flow Stress

Answer 9

The stress level above yielding; stress level required to keep the material flowing

Question 10

What is hot working of metals and what does it do to grain structures

Answer 10

Shaping preheated material at temperature above the recrystallization temperature where material stiffness and yield stress is low.

Refines grains through recrystallization; Course or dendritic grains are broken up as small grains form. Grains simultaneously may be stretched along the flow direction which results in a higher strength in preferred direction

Question 11

Flow direction

Answer 11

Direction of tensile stress in hot/cold working