Multiple Choice Questions (MCQ)

Unit-2: Metal Forming Process

1.The process used to improve fatigue resistance of the metal by setting up compressive stresses in its
surface, is known as
a)Hot piercing
b) Extrusion
c) cold peening
(d) cold heading

ANSWER: c

2.a moving mandrel is used in

(a)Wire drawing
(b)Tube drawing
(c)Metal cutting
(d)Forging

ANSWER:b

3.Which of the following methods can be used for manufacturing 2 meter long seamless metallic tubes?
a)drawing
b)Extrusion
c)Rolling
d)Extrusion and rolling

ANSWER: d

4.The minimum size of a bloom is

a)5 cm × 5 cm
b)10 cm × 10 cm
c)15 cm × 15 cm
d)20 cm × 20 cm

ANSWER:c

5.In a our high rolling mill, the diameter of backing up rolls is ________ the diameter of working rolls.
(a)Equal to
(b)Smaller than
(c)Larger than
(d)None of these

ANSWER: c

6.In which of the following extrusion operation is friction a factor in determining the extrusion force (one
best ANSWER):
(a) direct extrusion
(b) indirect extrusion?
ANSWER a

7.Hot extrusion involves prior heating of billet to a temperature above its

_____________.

ANSWER: crystallization temperature.

8.a standard method of measuring capacity of maximum size of extrudable cross section is in terms
of________________.

ANSWER:circumscribing–circle-diameter (ccd).

9.The ratio of length to thickness of any extrudable segment should not exceed
_______________.

ANSWER:14:1

10.Symmetrical cross sections are preferable to non-symmetrical designs to avoid ________

ANSWER:Unbalanced stresses and warpage

11.The triple action for clamping material during blanking provides

(a)V-ring pressure
(b)counter pressure
(c)all of the above
(d)none of these

ANSWER:c

12.Which of the following is false regarding blanking

(a)better surface finish
(b)squared sheared edges
(c)low dimensional accuracy
(d)better flatness or appearance

ANSWER:c

13.Which of the following materials cannot be blanked?

(a)steel with carbon content of 0.08 to 0.35 %

(b)brasswith lead content
(c)copper
(d)aluminium

ANSWER:b

14.Which of the following is false regarding design recommendation for blanking?

(a)corners for fine blanked parts must be rounded
(b)hole diameter should be approximately 20 to 25% of the material thickness
(c)pitch circle radius for tooth form is 60% of material thickness
(d)maximum depth to which semi piercing are to be pierced is 70% of material thickness
ANSWER:b

15.The flatness obtained for piece-part in production varies widely with respect to
(a)part size
(b)part configuration and quality
(c)thickness of material
(d)all of the above

ANSWER:d

16.In the impact extruded products are of _______ material.

(a)aluminum
(b)al alloys
(c)Ferrous
(d)Nonferrous

ANSWER:d

17.In the Impact extrusion process, base must be _______ to/than the sidewalls
(a)Thicker
(b)Equal
(c)Thinner
(d)Thicker or thinne

ANSWER:d

18.Impact extruded parts should be symmetrical in order to _________.

(a)minimize tooling deflection
(b)maintain unequal wall thickness
(c)both a & b
(d)Neither a nor b

ANSWER:c

19.what is the maximum recommended height of internal ribs

in the extruded part?
(a)½ of the wall thickness
(b)2 times the wall thickness
(c)3 times the wall thickness
(d)Same as the wall thickness

ANSWER:c

20.Inclined bottom surfaces, with a desired inclination of ___, near the sidewalls assist metal flow in
backward extrusion
(a)80 deg
(b)75 deg
(c)120 deg
(d)50 deg
ANSWER:c

21.at what length-diameter ratio, Forward extrusions can be made?

(a)25:1
(b)50:1
(c)75:1
(d)100:1
ANSWER:d

22.Side wall can be made with zero draft.

(a)True
(b)False

ANSWER:a

23.Flange should be placed _____of the part for forward extrusion

(a)at the start
(b)at the middle
(c)at the end
(d)anywhere

ANSWER:c

24.For a forward extruded part fillet is required at the junction between

(a)Flange and sidewall
(b)bottom and the side wall
(c)both a and b
(d)None of the above

ANSWER:a

25.For forward extrusion sidewalls has to be _____

(a)Straight
(b)Tapered
(c)Either a or b

ANSWER:c

26.Good surface finish and better dimensional accuracy can be achieved in

(a)cold working process
(b)hot working process
(c)both a. and b.
(d)none of the above

ANSWER: a

27.Mechanical working processes are performed on metals

(a)to achieve optimum mechanical properties in the metal
(b)to improve the mechanical strength of the metal
(c)to make metal dense
(d)all of the above
ANSWER: d

28.Hot working process is the plastic deformation of metal which is carried out
(a)at temperature below the recrystallisation temperature
(b)at temperature above the recrystallisation temperature
(c)at temperature equals to boiling point of water
(d)none of the above

ANSWER: b

29.Which of the following are the cold working processes?

(1) Forging
(2) bending
(3) Squeezing
(4) Pipe Welding
(5) drawing
(a)(1), (2) and (3)
(b)(2), (3) and (5)
(c)(2), (4) and (5)
(d)(1), (2), (3) and (5)

ANSWER: b

30.Worm working or semi-hot working process, which is the plastic deformation of metal or alloy under
conditions of temperature and strain rate, is performed to eliminate drawbacks of
(a)cold working process
(b)hot working process
(c)both cold and hot working processes
(d)none of the above

ANSWER: c

31.The volume of metal that enters the rolling stand

(a)should increase after rolling process
(b)should decrease after rolling process
(c)should remain same after rolling process
(d)unpredictable

ANSWER: c

32.Which characteristic of material is used in forging process?

(a)characteristics of elasticity of material
(b)characteristics of ductility of material
(c)characteristics of plasticity of material
(d)none of the above

ANSWER: c

33.How does the ability of material to withstand unpredictable loads change after forging?
(a)The ability of material to withstand unpredictable loads increases after forging
(b)The ability of material to withstand unpredictable loads decreases after forging
(c)The ability of material to withstand unpredictable loads does not change after forging
(d)Unpredictable

ANSWER: a

34.atch the following Tools used in smithy in Group 1 with their applications in Group 2 and select the
correct option.

1. Sledge hammers, straight, flat and cross peen ----a. To nick the bar and to shape the cold work
2. Smith ball peen hammer -----b. To make recesses of any shape in hot metal
3. Punches ---------------------------c. To cut plates to curves
4. Hardie -----------------------------d. To forge art, bend and shape the work
5. anvil -------------------------------E. To forge light and medium work
6. Gouge -----------------------------F. To forge big jobs
a. 1-(E), 2-(F), 3-(a), 4-(b), 5-(c), 6-(d)
b. 1-(E), 2-(F), 3-(b), 4-(a), 5-(d), 6-(c)
c. 1-(F), 2-(E), 3-(a), 4-(b), 5-(c), 6-(d)
d. 1-(F), 2-(E), 3-(b), 4-(a), 5-(d), 6-(c)

ANSWER: d

35.The plastic deformation of metal takes place when the stress induced in the metal, due to the applied
forces, reached the
(a)Yield point
(b)Proportional limit
(c)Fatigue strength
(d)Ultimate strength
(ANSWER:a

36.The process of formation of new grains is known as

(a)Pre-crystallization
(b)Re-crystallization
(c)crystallization
(d)Post-crystallization
(ANSWER:b)

37.In deformation by slip, the deformation of metal takes place along

(a)slip point
(b)slip line
(c)slip plane
(d)any of the above
(ANSWER:c)

38.In deformation by twin, deformation occurs along two ____ planes

(a)parallel
(b)perpendicular
(c)inclined
(d)any of the above
(ANSWER:a)
39.The hot working of metal, is accomplished at
(a)below recrystallization temperature
(b)above recrystallization temperature
(c)recrystallization temperature
(d)any of the above
(ANSWER:b)

40.Following are the advantages of hot working of metals, except

(a)close tolerances can be maintained
(b)porosity of the metal is minimized
(c)grain structure of the metal is refined
(d)no residual stresses are introduced
(ANSWER:a)

41.Which of the following process is used to convert larger sections, such as ingots into smaller sections?
(a)hot rolling
(b)hot forging
(c)hot spinning
(d)hot extrusion
(ANSWER:a)

42.The following are true for rolling, except

(a)velocity of metal at exit is same as that at the entry
(b)grains are elongated in the direction of rolling
(c)after crossing the stress zone the grain starts refining
(d)the greater the coefficient of friction more the possible reduction
(ANSWER:a)

43.In rolling, the pressure is maximum at

(a)entrance
(b)exit
(c)both the extremities
(d)at a point somewhat between the two extremities
(ANSWER:d)

44.In rolling, the point of maximum pressure is called

(a)no slip point
(b)slip point
(c)neutral point
(d)extreme point
(ANSWER:a)

45.In rolling, at point of maximum pressure

(a)metal moves faster than the roll surface
(b)metal moves slower than the roll surface
(c)both metal and roll surface moves at same speed
(d)any of the above can be possible
(ANSWER:c)

46.Tubes can be manufactured by

(a)hot forging
(b)hot spinning
(c)hot extrusion
(d)hot rolling
(ANSWER:c)

47.during extrusion of steel, adequate lubrication around the billet is done by providing a coating of
(a)vegetable oil
(b)graphite
(c)water
(d)powdered glass
(ANSWER:d)

48.In backward or indirect extrusion, _____ plunger is used

(a)solid
(b)hollow
(c)no
(d)both solid and hollow
(ANSWER:b)

49.Which of the following is true for hot extrusion?

(a)less force is required in forward extrusion as compared to backward extrusion
(b)more force is required in forward extrusion as compared to backward extrusion
(c)same force is applied in both forward and backward extrusion
(d)any of the above
(ANSWER:b)

50.all methods are used for producing tubes except

(a)hot spinning
(b)hot extrusion
(c)hot drawing
(d)hot piercing
(ANSWER:a

51.The cold working of metal is accomplished at

(a)below re-crystallization temperature
(b)below re-crystallization temperature
(c)re-crystallization temperature
(d)any of the above
(ANSWER):a

52.Which of the following is not improved by cold working of metals?

(a)hardness
(b)toughness
(c)surface finish
(d)corrosion resistance
(ANSWER:d)

53.Which of the following operation can be performed on lathe?

(a)spinning
(b)drawing
(c)coining
(d)swaging

(ANSWER:d)

54.Tubes for shaving cream and tooth paste are made by

(a)forward extrusion
(b)backward extrusion
(c)impact extrusion
(d)all of the above
(ANSWER:c)

55.Medals are made by

(a)spinning
(b)coining
(c)embossing
(d)bending
(ANSWER:c)

56.Which of the following is not true for cold working of metals?

(a)residual stresses are set up in the metal
(b)stress required to cause deformation is less than hot working of metals
(c)it reduces the corrosion resistance of the metal
(d)distortion of grains takes place in most of the cold working processes
(ANSWER:b)

57.Wires are made by

(a)spinning
(b)drawing
(c)embossing
(d)bending
(ANSWER:b)

58.Ornamental wares are made by

(a)spinning
(b)drawing
(c)embossing
(d)bending
(ANSWER:c)

59.all processes are formed in both hot and cold working except
(a)forging
(b)piercing
(c)drawing
(d)extrusion
(ANSWER:d)

60.Which of the following not a hot working process?

(a)extrusion
(b)drawing
(c)embossing
(d)piercing
(ANSWER:c)

61.The cold chisels are made by

(a)rolling
(b)piercing
(c)forging
(d)drawing
ANSWER:c

62.Which of the following options best describes the centre lathes?

(a)Machining machines
(b)Shaping machines
(c)Turning machines
(d)None of the above
ANSWER: c

63.assume a machining process of taper turning. In this process, a large diameter of taper is 'd' and it is
uniformly decreased to the small diameter of the taper 'd' at the horizontal length of tapered part of
workpiece is 'L'. What is the correct formula for half of tapper angle (2a / 2)?
(a)a = sin–1 ((d – d) / 2L)
(b)a = cos–1 ((d – d) / 2L)
(c)a = tan–1 ((d – d) / 2L)
(d)a = cot–1 ((d – d) / 2L)
ANSWER: c

64.Good surface finish and better dimensional accuracy can be achieved in

(a)cold working process
(b)hot working process
(c)both a. and b.
(d)none of the above
ANSWER: a

65.Which type of process the machining can be?

(a)cold working
(b)Hot working
(c)both a. and b.
(d)None of the above

ANSWER: a
66.When the tool of centre lathe moves perpendicular to the axis of rotation,
a. it produces a cylindrical surface
b. it produces a flat surface
c. it produces a tapered surface
d. none of the above
ANSWER: b

67.Worm working or semi-hot working process, which is the plastic deformation of metal or alloy under
conditions of temperature and strain rate, is performed to eliminate drawbacks of
a. cold working process
b. hot working process
c. both cold and hot working processes
d. none of the above

ANSWER: both cold and hot working processes

68.The metal joined is never brought to a molten stage in

a. pressure welding
b. fusion welding
c. thermit welding
d. none of the above
ANSWER: a

69.Which of the following is an example of fusion welding?

a. atomic hydrogen welding
b. Flash welding
c. Seam welding
d. Spot welding
ANSWER: a

70.as compared to the arc welding, the gas welding takes

a. considerably less time for the metal to heat up
b. considerably more time for the metal to heat up
c. approximately same time for the metal to heat up as arc welding
d. unpredictable
ANSWER: b

71.Power consumption in d.c. arc welding is

a. less than the power consumption in a.c. arc welding
b. more than the power consumption in a.c. arc welding
c. similar to the power consumption in a.c. arc welding
d. very difficult to calculate
ANSWER: b

72.Recrystallization temperature is a temp.

a)Phase change occur in metal
b)alloy changes into different constituents in solid states
c) min. temp. at which new,equiaxis grain form
d)None of above
ANSWER:c

73.In hot working, Working temp is,

a) above Trecrystallization temp.
b)below Trecrystallization temp.
c) Room temperature
d) None of above
ANSWER:a

74.This types of rolling mills metal is reduced by both horizontal & vertical rolls
a) Two high roller mills
b) Universal rolling mills
c) Planetary rolling mills
d) Tendem rolling mills
ANSWER:b

75.cold working of metal increases

a) tensile strength
b) yield stress
c) hardness
d) all of the above
ANSWER:d

76.The ductility of material with work hardening

a) increases
b) decreases
c) remain unchanged
d)can not predicted
ANSWER:b

77.The ability of material to be rolled into very thin foils depend up on its
a) strength
b) toughness
c) ductility
d)malleability
ANSWER:d

78.at the point of no slip in rolling the velocity of the work piece relative to surface speed of the rolls is
a) higher
b) lower
c) equal
d) there is no relation between the two
ANSWER:c

79.Which of following process produce strongest components

a) die casting
b) forging
c) hot rolling
d) extrusion
ANSWER:b

80.Upsetting in forging process meANSWER

a) distributed by misalignment of dies
b) spoiled due to overheating
c) done to increase the c/s area at the cost of length
d) done to increase the length at the cost of c/s area
ANSWER:c

81.In rolling process a sheet of 2.5 mm thickness. The diameter of the rolls is 600 mm& speed is 100 rpm
.The roll strip contact length will be,
a) 25mm
b) 39mm
c) 75mm
d) 120mm
ANSWER:b

82.The extrusion process most suitable for production of toothpastes tubes is

a) forward hot extrusion
b) backward hot extrusion
c) forward cold extrusion
d) Impact extrusion
ANSWER:d

83.In cold working operation drawing pressure against the die is

a) below yield point
b) between yield point &ultimate tensile strength
c) above ultimate strength
d) equal to ultimate strength
ANSWER:b

84.Long steel wires can be manufactured by

a) deep drawing
b) forging
c) drawing
d)extrusion
ANSWER:c

85.Types of friction observed when forging a disc is

a) sticking friction throughout
b) sliding friction throughout
c) Part of sticking & Part of sliding friction
d)none
ANSWER:c

86.components which are heavily cold worked may require

a) hardening
b) tempering
c) annealing
d) normalizing
ANSWER:b

87.Fatigue strength of work piece can be increased by

a) rotary swaging
b) hot rolling
c) shot peening
d) repeated bending
ANSWER:c

88.In an open die forging operation flow of metal is

a) completely constrained
b) not constrained at all
c) constrain only in horizontal direction
d) constrain only in vertical direction
ANSWER:d
89.drop forging is example of
a) open die forging
b) closed die forging without flash
c) smith forging
d) closed die forging with flash
ANSWER:b

90.The Elastic strain obtained on applying stress to a materials

a) Time dependent
b) Partially Permanent
c) directly Proportional To Stress
d) Inversly Proportional To Stress
ANSWER:c

91.In extrusion process when die angle increases the required extrusion force
a) Increases
b) decreases
c) decreases & Then Increases
d)Increase &Then decreases
ANSWER:c

92.advantage of cold working is

a) better dimensional accuracy
b) better Surface Finish
c) Higher Strength
d) all Of These.
ANSWER:d

93.Typical hot working temperature range for steel is

(a)650–1050°c
(b)650–723°c
(c)500–910°c
(d)none of these.
ANSWER:a

94.The forging operation of “upsetting” is

(a)reverse of drawing down process
(b)it is a bending operation
(c)it is a drifting operation
(d)none of these
ANSWER a

95.“alligatoring” is a defect associated with(

(a)forging process
(b)casting process
(c)extrusion process
(d)rolling process.
ANSWER d

96.a “die” is used in(

(a)casting process
(b)extrusion process
(c)forging process
(d)all of these
ANSWER d

97.Out of the following, which is the defect which is not associated with casting process:
(a)blow holes
(b)Scale
(c)centre burst
(d)Hot tear
ANSWER c

98.Which “term” is not associated with casting process?

(a)Gate
(b)Runner
(c)Riser
(d)Swage.
ANSWER d

99.Fuel used in a cupola consists of

(a)steam coal
(b)furnace oil
(c)electricity
(d)hard coke
ANSWER d

100.Which allowance is not provided on the “pattern” made for a casting ?

(a)Machining allowance
(b)Solidification allowance
(c)draft allowance
(d)Shrinkage allowance.
ANSWER b

101.“blanking” is an expression used in(

(a)sheet metal work
(b)casting process
(c)drawing
(d)rolling
ANSWER a

102.In oxidizing flame, the inner core attains a temperature of …………….. °c.
(a)2100
(b)2800
(c)3150
(d)3500
(ANSWER: d)

103.arc blow occurs in …………. Welding.

(a)ac
(b)dc
(c)Gas
(d)Resistance
(ANSWER: b)

104.The connecting rods of Ic engines are manufactured using the process of ………
(a)extrusion
(b)drop forging
(c)rolling
(d)spinning
(ANSWER: b)

105.Plastic bottles are manufactured using the process of

(a)blow moulding
(b)injection moulding
(c)atomizing
(d)die casting
(ANSWER: a)

106.Operation of bending a partially cut hole on one side is called ………….

(a)nibbling
(b)slitting
(c)lancing
(d)spiral
(ANSWER: c)