Assignment II

Q1) Write characteristics, advantages and disadvantages of “Hot working” and “cold
working” processes.
Q2) What do you mean by metal forming?

Q3) Why forging is preferred over casting?

Q4) Briefly discuss following “Basic foraging Operations” Upsetting, Heading,
Fullering, Edging and drawing down
Q5) Define upsetting. Explain smith forging with diagram.

Q6) Explain the preliminary stages of forging a hook.

Q7) What are the considerations in upset forging dies design?
Q8) Define flash and gutter in reference of forging.
Q9) List the defects normally found in the forged components with cause.
Q10) Explain forward and backward extrusion with their principle, advantages,
disadvantages and application.
Q11) Describe cold hydrostatic extrusion and give its advantages.
Q12) Define angle of angle of bite in rolling operation.
Q13) Classify the rolling mill on the basis of number of rolls in stand and discuss in
brief.
Q14) Explain roll pass sequences.
Q15) What are the different types of rolled products?
Q16) A 200 mm wide and 22 mm thick strip of metal fed through a pair of powered
rolls to reduce its thickness to 18 mm in a single pass. The rolls are of 500 mm diameter
and rotating at 60 rpm. If the coefficient of friction between the rolls and work interface
is taken as 0.15, determine whether or not the rolling operation is possible. If it is
possible, calculate the roll force.
Q17) In a single pass rolling operation, a 20 mm thick plate width of 100 mm, is
reduced to 18 mm. The roller radius is 250 mm and rotational speed is 10 rpm. The
average flow stress for the plate material is 300 MPa. What is the power required for the
rolling operation in kW.
Q18) Explain various methods for drawing tubes.
Q19) Discuss various methods for drawing tubes.
Q20) Explain wire drawing principle with diagram.
Q21) Define the following press working operations:
i)Blanking ii) Punching iii) Perforating
iv) Shaving v) Drawing vi) Bending
vii) Notching viii) Nibbling
Q22) A circular blank of 30 mm diameter is to be cut from 2mm thick 0.1 percent
carbon steel sheet. Determine the die and punch sizes. Also estimate the punch force and
the stripping force needed.
Q23) A 37.5 cm long, 19 cm wide and 2.5 mm thick strip is to be bent in a V-shaped
die. Calculate the bending force necessary if the steel has 630 N/mm2 tensile
strength.(Assume width of die opening is 16t)

Q24) Classify presses according to the type of frame.

Q25) Explain single action, double action and triple action presses.
Q26) Explain coining, spinning, stretch forming and embossing process with neat
sketch.

Q27) Define jigs and fixture.

Q28) Explain 3-2-1 principle applied to jigs and fixtures.
Q29) Write short note on thread rolling.
Q30) A 90o bend is to be made from steel sheet in air type of bending. The bend length
is 30 cm and stock thickness is 3 mm. the ultimate tensile strength is 400 MPa. The beam
length is 4 cm. Calculate the bending load. If bend is made by edge bending, when punch
and die radius is 10 mm, find the bending force required.