Assignment on Bulk-Forming Processes

Attempted any 40 questions, your answer should short with suitable diagram, you
need to submit your assignment till 6/6/2020, after submission we will have
interactive discussion on this assignment if required. Write your assignment write
page number along with your signature on every page and mail it to me before
deadline.

1. How are bulk deformation processes different from sheet forming operations?
Describe each.
2. What are some common bulk deformation processes ?
3. What are some of the common terms applied to the various sizes and shapes of
rolled products?
4. Why are hot-rolled shaped products generally limited to standard forms and sizes?
5. Why is it undesirable to minimize friction between the workpiece and tooling in a
rolling operation?
6. Why is it desirable to have uniform temperature when hot rolling a material?
7. Why is it important to control the finishing temperature of a hot-rolling operation?
8. What are some of the attractive attributes of cold rolling?
9. Discuss the relative advantages and typical uses of two-high rolling mills with large-
diameter rolls, three-high mills, and four-high mills.
10. Roll flexing can result in non uniform thickness in the rolled product. How do four-
high and cluster mills minimized this flexing?
11. Why is foil almost always rolled on a cluster mill?
12. Why is speed synchronization of the various rolls so vitally important in a
continuous or multiple-stand rolling mill?
13. Explain how hot-rolled products can have directional properties and residual
stresses.
14. Discuss the problems in maintaining uniform thickness in a rolled product and some
of the associated defects.
15. Why is a ‘‘crowned’’ roll always designed for a specific operation on a specific
material?
16. How might the addition of horizontal tensions act to improve the thickness
uniformity of rolled products?
17. What is thermomechanical processing, and what are some of its possible
advantages?
18. Provide a concise description of the forging process.
19. What are some of the types of flow that can occur in forging operations?
20. Why are steam or air hammers more attractive than gravity drop hammers for
hammer forging?
21. What is the difference between open-die and impression-die forging?
22. Why is open-die forging not a practical technique for large scale production of
identical products?
23. What additional controls must be exercised to perform flashless forging?
24. What is a blocker impression in a forging sequence?
25. For what types of forging products or conditions might a press be preferred over a
hammer?
26. Why heated dies are generally employed in hot-press forging operations?
27. Describe some of the primary differences among hammers, mechanical presses, and
hydraulic presses.
28. Why are different tolerances usually applied to dimensions contained within a
single die cavity and dimensions across the parting plane?
29. What are some of the roles played by lubricants in forging operations?
30. What are some of the attractive features of orbital forging?
31. What types of product geometry can be produced by orbital forging?
32. What is upset forging?
33. What are some of the typical products produced by upset forging operations?
34. What types of products can be produced by automatic hot forging?
35. What are some of the attractive features of automatic hot forging? What is a major
limitation?
36. How does roll forging differ from a conventional rolling operation?
37. What is swaging? What kind of products are produced?
38. How can the swaging process impart different sizes and shapes to an interior cavity
and the exterior of a product?
39. What are some possible objectives of near-net-shape forging?
40. Provide a concise definition of extrusion.
41. What metals can be shaped by extrusion?
42. What are some of the attractive features of the extrusion process?
43. What is the primary shape limitation of the extrusion process?
44. What is the primary benefit of indirect extrusion?
45. What property of a lubricant is critical in extrusion that might not be required for
processes such as forging?
46. What types of products are made using a spider-mandrel die? Why can lubricants
not be used in spider-mandrel extrusion?
47. What are some of the unique capabilities and special limitations of hydrostatic
extrusion?
48. What is the unique capability provided by pressure-to-pressure hydrostatic
extrusion?
49. How the feedstock is pushed through the die in continuous extrusion processes?
50. What types of feedstock can be used in continuous extrusion other than the
conventional solid rod?
51. Why are rods generally drawn on draw benches, while wire is drawn on draw block
machines?
52. Why is the reduction in area significantly restricted during wire, rod, and tube
drawing?
53. What is the difference between tube drawing and tube sinking?
54. For what types of products might a floating plug be employed?
55. What are the size limitations for the cold drawing of complex cross-section steel
products?
56. What types of materials are used for wire-drawing dies?
57. What types of products are produced by cold heading?
58. What is impact extrusion, and what variations exist?
59. If a product contains a large-diameter head and a small diameter shank, how can the
processes of cold extrusion and cold heading be combined to save metal?
60. What are some of the attractive properties or characteristics of cold-forming
operations?
61. How might cold forming be used to substantially reduce material waste?
62. What processes can be used to produce seamless pipe or tubing?
63. What type of products can be made by the roll-extrusion process?
64. How is coining different from a process known as embossing?
65. Why might hubbing be an attractive way to produce a number of identical die
cavities?
66. How might a peening operation increase the fracture resistance of a product?
67. What is burnishing?