FORMING QUESTIONS

1. Calculate the bite angle when rolling plates 12 mm thick using work rolls 600 mm
diameter and reducing the thickness by 3 mm

2. A strip with cross-sectional area 150 mm x 4.5 mm is being rolled with 20% reduction of
area using 450 mm diameter rollers. The angle subtended by the deformation zone at the
roll centre is (in radians)
(a) 0.01 (b) 0.02 (c) 0.03 (d) 0.06

3. In a rolling process, sheet of 25mm thickness is rolled to 20mm thickness. Roll is of

diameter 600mm and it rotates at 100 rpm. The roll strip contact length will be
(a) 5mm b) 39mm (c) 78mm d) 120mm

4. A 4 mm thick sheet is rolled with 300 mm diameter rolls to reduce thickness without
any change in its width. The friction coefficient at the work-roll interface is 0.1. The
minimum possible thickness of the sheet that can be produced in a single pass is
(a) 1.0 mm (b) 1.5 mm (c) 2.5 mm (d) 3.7 mm

5. The thickness of a metallic sheet is reduced from an initial value of 16 mm to a final

value of 10 mm in one single pass rolling with a pair of cylindrical rollers each
of diameter of 400 mm. The bite angle in degree will be
(a) 5.936 (b) 7.936 (c) 8.936 (d) 9.936

6. In a single pass rolling operation, a 20 mm thick plate with plate width of 100 mm, is
reduced to18mm. The roller radius is 250 mm and rotational speed is 10 rpm. The
average flow stress for the plate material is 300 MPa. The power required for the rolling
operation in kW is closest to
a) 15.2 (b) 18.2 c) 30.4 (d) 45.6

7. In a single pass rolling process using 410 mm diameter steel rollers, a strip of width 140
mm and thickness 8 mm undergoes 10% reduction of thickness. The angle of bite in
radians is
(a) 0.006 (b) 0.031 (c) 0.062 (d) 0.600

8. If the elongation factor during rolling of an ingot is 1.22 The minimum number of passes
needed to produce a section 250 x 250 mm from an ingot of 750 x 750 mm are
(a) 8 (b) 9 (c) 10 (d) 12
9. A copper strip of 200mm width and 30mm thickness is to be rolled to a thickness of
295mm. The roll of radius 300mm rotates at 100 rpm. The average shear strength of the
work material is180 MPa. The roll strip contact length and the roll force are
(a) 15.8 mm and0.569 MN (b) 18.97 mm, 0.683 MN
(c) 38.73 mm and1.395 MN (d) 38.73 mm and 2.09 MN
10. In a rolling process, thickness of a strip is reduced from 4 mm to 3 mm using 300 mm
diameter rolls rotating at 100 rpm. The velocity of the strip (in m/sec) at the neutral point
is
(a) 1.57 (b) 3.14 (c) 47.10 (d) 94.20

11. The thickness of a plate is reduced from 30 mm to 10 mm by successive cold rolling

passes using identical rolls of diameter 600 mm. Assume that there is no change in width.
If the coefficient of friction between the rolls and the workpiece is 0.1, the minimum
number of passes required is
(a) 3 (b) 4 (c) 6 (d) 7

12. In a slab roiling operation, the maximum thickness reduction (Δhmax) is given by
Δhmax= µ^2R, where R is the radius of the roll and µis the coefficient of friction
between the roll and the sheet. If µ = 0.1, the maximum angle subtended by the
deformation zone at the centre of the roll (bite angle in degree) is__________

13. In a rolling operation using rolls of diameter 500 mm if a 25 mm thick plate cannot be
reduced to less than 20 mm in one pass, the coefficient of friction between the roll and
the plate is______

14. A wire of 0.1 mm dia is drawn from a rod of 15mm diameter dies giving reductions of
20%, 40% and 80% are available. For minimum error in the final size, the number of
stages and reduction at each stage respectively would be
(a) 3 stages and 80% reduction for all three stages
(b) 4 stages and 80% reduction for first three stages followed by a finishing stage of 20%
reduction
(c) 5 stage and reduction of 80%, 80%, 40%, 20% is sequence
(d) None of these

15. In a wire drawing operation, diameter of a steel wire is reduced from 10 mm to 8

mm. The mean flow stress of the material is 400 MPa. The ideal force required for
drawing (ignoring friction and redundant work) is
(e) (a) 4.48 kN (b) 8.97 kN (c) 20.11 kN (d) 31.41 kN
16. An annealed copper wire of 25 mm diameter drawn into a wire of 5 mm diameter. The
average yield stress in this operation if the curve of the material is given = σ = 315 ε 0.54
MPa
(f) (a) 592 MPa (b) 458 MPa (c) 342 MPa (d) None of these
A 10 mm diameter annealed steel wire is drawn through a die at a speed of 0.5 mls to
reduce the diameter by 20%. The yield stress of the material is 800 MPa.
17. Neglecting friction and strain hardening, the stress required for drawing (in MPa) is
(a) 178.6 (b) 357.0 (c) 1287.5 (d) 2575.0

18. The power required for the drawing process (in kW) is
(a) 8.97 (b) 14 (c) 17.95 (d) 28

19. In a two-stage wire drawing operation, the fractional reduction (ratio of change in cross
sectional area to initial cross-sectional area) in the first stage is 0.4. The fractional
reduction in the second stage is 0.3. The overall fractional reduction is
(b) (a) 0.24 (b) 0.58 (c) 0.60 (d) 1.00

20. In open die forging, a disc of diameter 200 mm and height 60mm is compressed without
any barreling effect. The final diameter of the disc is 400 mm. The true strain is
(a) 1.986 (b) 1.686 (c) 1.386 (d) 0.602

21. A solid cylinder of diameter 100 mm and height 50 mm is forged between two
frictionless flat dies to a height of 25 mm. The percentage change in diameter is
(a) 0 (b) 2.07 (c) 20.7 (d) 41.4

22. A solid cylindrical stainless steel work piece of 200 mm diameter and 150 mm height.
This component is reduced by 50% in height with flat die in open die forging. Assuming
the flow stress of the material as 1000 MPa and the coefficient of friction to be 0.2 , the
estimated forging force at the end of the stroke is
(a) 20.8 kN (b) 31 kN (c) 78.6 kN (d) 78.6 MN

23. A brass billet is to be extruded from its initial diameter of 100 mm to a final diameter of
50 mm. The working temperature of 700ce and the extrusion constant is 250 MPa. The
force required for extrusion is
(a) 5.44 MN (b) 1.36 MN (c) 2.72 MN (d) 0.36 MN

24. A round billet made of brass is to be extruded (extrusion constant = 250 MPa) at 700°C.
The billet diameter is 100 mm and the diameter of the extrusion is 50 mm. The extrusion
force required (in MN) is
(a) 1.932 (b) 2.722 (c) 3.423 (d) 4.650