• -Describe the effects of rolling with too much back tension?

in this Case, the rollers rotate at a high speed and begin to slide as a result the
thickness will not be reduced evenly and the workpiece may break off
• -Why is thread rolling preferable than thread Cutting?
in the rolling of threads impart improved strength because of Cold working
and favorable grain flow Unlike in thread cutting which cuts through the
grains of the metal
• -List three different kinds of defects in flat rolling?
1- Alligatoring 2-Wary edges 3-edge Cracks
2- 4-Zipper cracks in the center of the strip
• -what are the function of rotating rolls in the rolling?
1. Pull the work into the gap between them by friction work part
and rolls
2. Simultaneously squeeze the work to reduce its Cross section
• -why is friction generally undesirable in metal-forming?
1- it inhibits metal flow during deformation Causing residual Stresses and
product defects
2- it increases force and power required
3- it increases wearing of the tools
• differences between bulk an sheet?
* Bulk
1. Significant deformation and massive shape change
2. Compressive deformation force.
3. Low Surface Area to Volume ratio
* Sheet
1. Called Press-working
2. performed (strips and Coils)
3. Use set of punch and die
4. High surface Area-to Volume ratio
• what products are produced by the upsetting process?
1- Nails 2- Heads 3-Bolts 4-screws
• what do you mean forgeability of metal?
The ability of a metal to undergo deformation without Cracking by
means of forging
• what are the Variables that determine the maximum draft in
the rolling operation?
dmax =M²R
1. -Coefficient of friction
2. -roll radius
• what is isothermal forming?
Isothermal forming is a manufacturing process in which a material is
formed into a-desired shape at constant temp S - this process heats
the dies to the same temp as that of the hot Workpiece.
• which of the rolling mill types are associated with relatively
Small diameter rolls in contact with work?
1. Four-high> backing rolls support smaller work rolls.
2. Cluster mill-> multiple backing rolls on smaller rolls
• my What is the reason barreling effect ?
1- friction between work and die surfaces
2- Temperature difference between work and die
• What happens in hot open-die forging ?
my heat transfer at die surface, which Cool the metal and Increases
resistance to deformation.
• my what are the advantages and Limitations of Cogging?
advantage:
1-Greater Strength 2. Less waste of metal
3. High hardness of the product. 4. good surface finish. Y
Disadvantage
1. requires high force 2. High energy Consumption.
2. 3- High tool wear 4- Long Time
• Should cogging be performed hot or Cold ?
- Cogging Should be performed a-hot because in hot working we get
plastic deformation. Lower force as result that Less energy and power
Consumption
-but typically Cogging performed in Cold because a lot of product in
Cogging It must be good property.