Question 1

In which of the following extrusion operations is friction a factor in determining the extrusion force:

Accepted Answer

A) direct extrusion 
B) indirect extrusion 
A) direct extrusion 
B) indirect extrusion A

Question 2

In metal extrusion, the extrusion ratio is also known by which of the following terms (one best answer):

Accepted Answer

A) area reduction 
B) draft 
C) reduction 
D) reduction ratio 
A) area reduction 
B) draft 
C) reduction 
D) reduction ratio D

Question 3

Which of the following stress or strength parameters is used in the computation of the maximum force in a forging operation (one best answer):

Accepted Answer

A) average flow stress 
B) compression strength 
C) final flow stress 
D) tensile strength 
E) yield strength 
A) average flow stress 
B) compression strength 
C) final flow stress 
D) tensile strength 
E) yield strength C

Question 4

Theoretically, the maximum reduction possible in a wire drawing operation, under the assumptions of a perfectly plastic metal, no friction, and no redundant work, is which one of the following:

Accepted Answer

A) zero 
B) 0.63 
C) 1.0 
D) 2.72 
A) zero 
B) 0.63 
C) 1.0 
D) 2.72

Question 5

Which of the following bulk deformation processes are involved in the production of nails for lumber construction (three best answers):

Accepted Answer

A) bar and wire drawing 
B) extrusion 
C) flashless forging 
D) impression die forging 
E) rolling
F)upsetting 
A) bar and wire drawing 
B) extrusion 
C) flashless forging 
D) impression die forging 
E) rolling
F)upsetting

Question 6

Which of the following stress or strength parameters is used in the computation of the force in an extrusion operation (one best answer):

Accepted Answer

A) average flow stress 
B) compression strength 
C) final flow stress 
D) tensile strength 
E) yield strength 
A) average flow stress 
B) compression strength 
C) final flow stress 
D) tensile strength 
E) yield strength

Question 7

Rolling is a bulk deformation process in which the thickness of the work is reduced by compressive forces exerted by two opposing rolls:

Accepted Answer

A) True 
 B)False

Question 8

Which of the following rolling mill types are associated with relatively small diameter rolls in contact with the work (two correct answers):

Accepted Answer

A) cluster mill 
B) continuous rolling mill 
C) four high mill 
D) reversing mill 
E) three high configuration 
A) cluster mill 
B) continuous rolling mill 
C) four high mill 
D) reversing mill 
E) three high configuration

Question 9

The starting workpiece in hot rolling of steel plate and sheet stock is which one of the following:

Accepted Answer

A) bar stock 
B) billet 
C) bloom 
D) slab 
E) wire stock 
A) bar stock 
B) billet 
C) bloom 
D) slab 
E) wire stock

Question 10

The maximum possible draft in a rolling operation depends on which of the following parameters (two correct answers):

Accepted Answer

A) coefficient of friction between roll and work 
B) roll diameter 
C) roll velocity 
D) stock thickness 
E) strain
F)strength coefficient of the work metal 
A) coefficient of friction between roll and work 
B) roll diameter 
C) roll velocity 
D) stock thickness 
E) strain
F)strength coefficient of the work metal

Question 11

Flash in impression die forging serves no useful purpose and is undesirable because it must be trimmed from the part after forming:

Accepted Answer

A) True 
 B)False

Question 12

Which of the following operations are closely related to open-die forging (three best answers):

Accepted Answer

A) cogging 
B) flashless forging 
C) fullering 
D) impression-die forging 
E) Mannesmann process
F)precision forging
G)upsetting 
A) cogging 
B) flashless forging 
C) fullering 
D) impression-die forging 
E) Mannesmann process
F)precision forging
G)upsetting

Question 13

Which of the following are alternative names for indirect extrusion (two correct answers):

Accepted Answer

A) backward extrusion 
B) direct extrusion 
C) forward extrusion 
D) impact extrusion 
E) reverse extrusion 
A) backward extrusion 
B) direct extrusion 
C) forward extrusion 
D) impact extrusion 
E) reverse extrusion

Question 14

Production of tubing is possible in indirect extrusion but not in direct extrusion:

Accepted Answer

A) True 
 B)False

Question 15

Which of the following stress or strength parameters is used in the computation of rolling force (one best answer):

Accepted Answer

A) average flow stress 
B) compression strength 
C) final flow stress 
D) tensile strength 
E) yield strength 
A) average flow stress 
B) compression strength 
C) final flow stress 
D) tensile strength 
E) yield strength

Question 16

Which of the following are basic bulk deformation processes in metal forming (three correct answers):

Accepted Answer

A) bar drawing 
B) blanking 
C) deep drawing 
D) extrusion 
E) forging
F)stamping 
A) bar drawing 
B) blanking 
C) deep drawing 
D) extrusion 
E) forging
F)stamping

Question 17

Production of pipes and tubes is associated with which of the following bulk deformation processes (three correct answers):

Accepted Answer

A) extrusion 
B) hobbing 
C) ring rolling 
D) roll forging 
E) roll piercing
F)tube sinking
G)upsetting 
A) extrusion 
B) hobbing 
C) ring rolling 
D) roll forging 
E) roll piercing
F)tube sinking
G)upsetting

Question 18

Johnson's formula is associated with which one of the four bulk deformation processes:

Accepted Answer

A) bar and wire drawing 
B) extrusion 
C) forging 
D) rolling 
A) bar and wire drawing 
B) extrusion 
C) forging 
D) rolling

Question 19

Furnaces used to heat cast steel ingots to achieve a uniform temperature throughout prior to rolling are called which of the following (one best answer):

Accepted Answer

A) annealing furnaces 
B) heat treating ovens 
C) soaking pits 
D) tempering furnaces 
A) annealing furnaces 
B) heat treating ovens 
C) soaking pits 
D) tempering furnaces

Question 20

Which of the following are classified as forging operations (four correct answers):

Accepted Answer

A) coining 
B) fullering 
C) impact extrusion 
D) roll piercing 
E) swaging
F)thread rolling
G)trimming
H)upsetting 
A) coining 
B) fullering 
C) impact extrusion 
D) roll piercing 
E) swaging
F)thread rolling
G)trimming
H)upsetting

Exam 15: Bulk Deformation Processes in Metal Workiing

In which of the following extrusion operations is friction a factor in determining the extrusion force:

In metal extrusion, the extrusion ratio is also known by which of the following terms (one best answer):

Which of the following stress or strength parameters is used in the computation of the maximum force in a forging operation (one best answer):

Theoretically, the maximum reduction possible in a wire drawing operation, under the assumptions of a perfectly plastic metal, no friction, and no redundant work, is which one of the following:

Which of the following bulk deformation processes are involved in the production of nails for lumber construction (three best answers):

Which of the following stress or strength parameters is used in the computation of the force in an extrusion operation (one best answer):

Rolling is a bulk deformation process in which the thickness of the work is reduced by compressive forces exerted by two opposing rolls:

Which of the following rolling mill types are associated with relatively small diameter rolls in contact with the work (two correct answers):

The starting workpiece in hot rolling of steel plate and sheet stock is which one of the following:

The maximum possible draft in a rolling operation depends on which of the following parameters (two correct answers):

Flash in impression die forging serves no useful purpose and is undesirable because it must be trimmed from the part after forming:

Which of the following operations are closely related to open-die forging (three best answers):

Which of the following are alternative names for indirect extrusion (two correct answers):

Production of tubing is possible in indirect extrusion but not in direct extrusion:

Which of the following stress or strength parameters is used in the computation of rolling force (one best answer):

Which of the following are basic bulk deformation processes in metal forming (three correct answers):

Production of pipes and tubes is associated with which of the following bulk deformation processes (three correct answers):

Johnson's formula is associated with which one of the four bulk deformation processes:

Furnaces used to heat cast steel ingots to achieve a uniform temperature throughout prior to rolling are called which of the following (one best answer):

Which of the following are classified as forging operations (four correct answers):

Introduction and Overview of Manufacturing

The Nature of Materials

Mechanical Properties of Materials

Physical Properties of Materials

Engineering Materials

Dimensions, Surfaces, and Their Measurement

Fundamentals of Metal Casting

Metal Casting Processes

Glassworking

Shaping Processes for Plastics

Processing of Polymer Matrix Composites and Rubber

Powder Metallurgy

Processing of Ceramics and Cermets

Fundamentals of Metal Forming

Sheet Metalworking

Theory of Metal Machining

Machining Operations and Machine Tools

Cutting Tool Technology

Economic and Product Design Considerations

Grinding and Other Abrasive Processes

Nontraditional Machining and Thermal Cutting

Heat Treatment of Metals

Surface Processing Operations

Fundamentals of Welding

Welding Processes

Brazing, Soldering, and Adhesive Bonding

Mechanical Assembly

Rapid Prototyping and Additive Manufacturing

Processing of Integrated Circuits

Electronics Assembly and Packaging

Microfabrication Technologies

Nanofabrication Technologies

Automation Technologies for Manufacturing Systems

Integrated Manufacturing Systems

Process Planning and Production Control

Quality Control and Inspection

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