Chapter 18

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1. 1. Why are bulk 1. Capable of significant shape change 10. 10. What is reversing mill in A two high rolling mill where
deformation when hot working is used. rolling? the direction of rotation of
processes rolls can be reversed to
important 2. Positive effect on part strength when allow for work to pass
commercially cold working is used. through from either side.
and
11. 11. Besides flat rolling and Some other processes that
technologically? 3. Most processes include little material
shape rolling, identify some use rolls are ring rolling,
waste and they are net shape processes
additional bulk forming thread rolling, gear rolling,
2. 2. Name the four Rolling, forging, extrusion and wire and bar processes that use rolls to roll
bulk drawing effect the deformation. piercing, and roll forging.
deformation
12. 12. what is forging? Forging is a deformation
processes.
process in which the
3. 3. What is rolling When slab's or plate's thickness is reduce workpiece is compressed
in the context of by compression in between opposing rolls. between two
bulk dies, using impact or gradual
deformation pressure to form the part.
process?
13. 13. Name the three basic Open die
4. 4. In rolling of A bloom is a rolled steel workpiece with a types of dies in forging. Impression die
steel, what are square cross section of about 150 mm by Flashless die
the differences 150 mm. The starting work unit for a bloom
14. 14. Why is flash desirable in Flash acts as a constrain for
between a is an ingot heated in a soaking pit. A slab is
impression die forging? the metal to properly flow
bloom, a slab, rolled from an ingot or a bloom and has a
through cavity.
and a billet? rectangular cross section of about 250 mm
by 40 mm. A billet is rolled from a bloom 15. 15. What is trimming A trimming operation where
and has a square cross section of about 40 operation in context of the flash is removed by
mm by 40 mm. impression die forging? shearing.

5. 5. List some Sheet stock, I-beam, U-beam, rails for 16. 16. Two basic types forging Forging hammers and
products railroad tracks and round and bar stock equipment? forging presses
produced on a 17. 17. What is isothermal Isothermal forging is a hot
rolling mill? forging? forging operation in which
6. 6. What is draft The difference between initial and final the die surfaces are heated
in rolling thickness of workpiece as it passes the to reduce heat transfer from
operation? rolls. the work into the tooling

7. 7. What is condition in hot rolling in which the surface 18. 18. What is extrusion? A deformation process
sticking in a hot of the workpiece adheres to the where a ram pushes the
rolling rolls as the piece passes between the rolls, metal workpiece through an
operation? causing severe deformation of the metal open die to get a desired
below the surface cross section.
in order to allow passage through the roll 19. 19. Distinguish between Direct has a flow in direction
gap. direct and indirect extrusion. of ram.
8. 8. Identify ways Different configuration of rolling mills to
in which force in reducing diameter of rolls, use hot rolling Indirect has metal flow in
flat rolling can and reduce draft in each pass. opposite direction of ram.
be reduced? 20. 20. Name some products Slide door railings, door and
9. 9. What is a two- consists of two opposing rolls between produced by extrusion? window frames, door
high rolling mill? which the work is handles, aluminum beverage
compressed. cans.
21. 21. Why is friction a factor in determining ram force in
direct extrusion but not a factor in indirect extrusion?
22. 22. What does the centerburst defect in extrusion have
in common with the roll piercing process?
23. 23. Define wire drawing and bar drawing
24. 24. How do compressive stresses play a role in wire
drawing?
25. 25. In wire drawing, why must drawing stress NEVER
exceed yield strength of work metal?
Because in direct extrusion the metal workpiece can have friction with
container. In indirect metal work piece does not touch the container.
movement on the outside affects the inside
Wire and bar drawing are bulk deformation processes in which the cross
section of a
wire or bar is reduced by pulling (drawing) it through a die opening
Compressive forces are present as metal workpiece is compressed as it
is forced the approach of the die opening.
Because instead of forcing the metal through the opening we would be
stretching it through the opening.