29 Questions
What is the main purpose of metal forming processes?
To transform simple geometry into complex parts
Which category do sheet metal forming operations fall under?
Sheet metal forming operations
How do rolls function in the rolling process?
By rotating to draw the work into the gap between them
In the context of metal forming, what is rolling primarily used for?
Reducing the thickness of a slab or plate
Which industry sectors benefit from items produced through metal forming processes?
Aeronautical and automotive industries
What distinguishes metal forming processes from other manufacturing methods?
Transforming simple geometry into complex shapes without changing mass or composition
What type of mill consists of upper and lower driven rolls and a middle roll that rotates by friction?
Three-high mill
In a cluster mill, how many backing rolls support each of the work rolls?
Two backing rolls
What is the purpose of feed rolls in a planetary mill operation?
To introduce the slab into the mill
What is the main characteristic of a cluster mill compared to a four-high mill?
Each work roll being supported by two backing rolls
What allows a planetary mill to hot reduce a slab directly to strip in one pass through the mill?
Pair of heavy backing rolls surrounded by planetary rolls
What is synchronized in continuous rolling or tandem mills to maintain consistent speed throughout the process?
Input speed of each stand
What is the angle subtended by the deformation zone at the center of the roll to achieve a 10% reduction in cross-sectional area of the strip after rolling?
6.84 degrees
For a strip with a cross-section of 150 mm x 4.5 mm and being rolled with a 20% reduction of area using 450 mm diameter rolls, what is the angle subtended by the deformation zone at the roll center in radians?
0.02 radians
In a rolling process where a sheet of 25 mm thickness is rolled to 20 mm thickness using a roll of diameter 600 mm rotating at 100 rpm, what will be the roll-strip contact length?
78 mm
What factor leads to an increase in the maximum possible draft in cold rolling of a sheet?
Decrease in coefficient of friction
How are seamless rings made in industry?
By a special rolling process called ring rolling
In a rolling process, which pair of parameters directly affects the maximum possible draft (difference between initial and final thickness) of the metal sheet?
Strain, Strength of the work material
What is the purpose of ring rolls in industrial processes?
Tube rolling and ring rolling
How are threads typically formed using the thread rolling technique?
By axial flow of material in the workpiece
What advantage do rolled threads have over cut threads?
Greater resistance to mechanical stress and increased fatigue strength
What happens to the grain structure of the material when threads are rolled?
The grain structure is distorted to follow the thread form
What is the entrance plane for a metal sheet entering the rolls in flat rolling analysis?
'xx' with a thickness 'h o'
What is the general guideline for flash thickness in forging?
3% of the maximum thickness of the forging
Why are draft angles necessary in almost all forging dies?
To facilitate removal of the part from the die
Why are internal draft angles typically made larger than external ones in forgings?
To improve metal flow into the die cavity
What is the adverse effect of small radii in forging?
Fatigue cracking of the dies
Why should machining allowance be provided in forging-die design?
To achieve final desired dimensions and surface finish
Where should machining allowance typically be provided in forging-die design?
At holes, at flanges, and at mating surfaces
Test your knowledge on metal forming processes, specifically rolling and forging techniques. Explore how materials are plastically deformed to create complex parts, without altering mass or composition. This quiz covers the basics of metal forming methods and their applications.
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