EXAMPLES OF POSSIBLE EXAMINATION SUBJECTS

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Sketch a section of a shape to indicate features to be found on all hot forgings.

Write brief comments on how they detract from a ready-to-use component
shape. Peripheral flash is typical on hot forged shapes; explain why this is so
and sketch an outline of the shape of a typical flash land and gutter used to
accommodate it. What considerations of die filling and forging load relate to
the dimensions of flash land and gutter?
A parting plane exists between top and bottom dies in hot forging tools. Using
a shape with deep ribs at its periphery show how the choice of the position of
the parting line can affect the ease with which the shape may be formed.
List the advantages of preforming in hot forging processes. What is the
purpose of a fullering operation? Explain, using sketches, how the crosssection variation in a long component to be hot forged is used to obtain an
idealised bar size and preform shape.
Sketch the layout of a hammer die and show the relations between fuller,
roller, mould and finisher cavities. Why is the distance of the mould cavity from
the centre-line of the dovetail about 3 times that of the finisher cavity?
Fuel fired, mainly gas, furnaces are widely used for preheating work-pieces.
By sketching the relation of heat input to charge (amount of metal contained in
the furnace at any time) briefly state the energy flow and explain how the
energy efficiency of such furnaces relates to the charge.
To increase heating rate a gas furnace can be set to a temperature higher
(temperature head) than that required for the charge. Using plots of typical
charge temperature against time in furnace, for different values of temperature
head, show the trend how, for a given required final charge temperature,
heating time can be varied.
Explain how load or air recuperation can increase the thermal efficiency of gas
fired furnaces.
Compare the advantages and disadvantages of gas fired furnaces and
induction heaters.
By using sketches, describe how, for a given frequency, maximum value of
primary current and bar composition, the magnitude of the induced current and
heater efficiency, depends on bar size.
What are the two mechanisms of heating by induction and how do they relate
to bar temperature?
Briefly describe the process of resistance heating, its advantages and
drawbacks. What is the main reason for it not being used extensively in
industry?
List and explain the main requirements of hot forging lubricants.
Explain with diagrams three means for measuring tool/work-piece friction and
describe the advantages and disadvantages of each.
Sketch the ideal load-stroke relation of a hydraulic press and list the
performance characteristics of the machine which illustrate its versatility.
Using a sketch, illustrate the kinematics of a mechanical (crank) press
showing the construction that, knowing the stroke of the press and the length

of the connecting rod enables the relation between available forging load and
crank position to be determined. Give this relation in defined symbols.
How is the practical maximum load capacity of a mechanical press defined?
During forging what limits the rate at which a mechanical press may be
operated?
Show with a sketch the typical load-stroke relation for a mechanical press and
use it to show how knowledge of the load requirement for a forging and the
positioning of forging tools relative to a press bed are important to avoid
stalling or structural damage of the machine..
Sketch the operating principle of a screw press. What is its source of forging
energy and illustrate diagrammatically a means for obviating overload.
Energy availability and maximum forging load of a screw press are related.
Sketch the relation of available energy to available load to show how flywheel
energy is distributed during a forging operation.
On a drop hammer potential energy is converted into kinetic energy, to
deform a work-piece, by allowing a ram to fall under gravity. Impact causes
the structure of the whole machine to move downwards, resulting in energy
loss. Assuming the machine to be rigid and all the kinetic energy to be
converted into either deformation or movement of the machine, knowing the
weight of the structure and the weight of the ram, derive an expression to
define the hammer efficiency. How is the efficiency of a drop hammer
enhanced in practice?
High efficiency can be obtained using two moving rams in a counterblow
hammer. Sketch one design of a counterblow hammer and briefly describe its
operating principle.
In a warm forging process, in contrast to hot forging, often the work-piece is
pierced before the finishing operation, with simple sketches illustrating forging
pressure distributions show the advantage of this.
Warm forging usually is performed in flashless tools which for solid part have
three basic components. Sketch the simplest tool design with a static
container and the design with a floating container. What are the advantages of
each design?

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