CONFIDENTIAL 2 EM/JUN 2015/MEM560

Chapter Three

a) Discuss three (3) for each advantages and disadvantages of hot working compared
to cold working processes.

(6 marks)
b) and illustrate one common defect in sheet metal bending operations.

(2 marks)
c) Explain 'No-draft forging' and give one disadvantage of this process.

(2 marks)

d) What is metal forming and discuss their contribution in manufacturing engineering.

(2 marks)

e) Suggest the suitable process to produce coins as shown in Figure Q2(b). With the
aids of sketches, explain the sequence of processes start from blanking part. (IMAGE
OF COIN WILL BE THERE )

f) List three (3) types of stamping processes and also three (3) types of forming
processes which are commonly available in sheet metal manufacturing industries.
(2 marks)

g) Hot working for metal involves plastic deformation above the recrystallization
temperature of the work material. Define the recrystallization temperature for the metal.

(2 marks)
h) Propose the most suitable metal forming process to manufacture the following engineering
products:

i) Crane hook
ii) Spanner
iii) Aluminium curtain railing for domestic application
iv) Electric power cable
v) Copper tube for air conditioning duct
vi) Steel T-section for building
(2 marks)

i) Crankshaft is an important automotive component. There are at least two (2) manufacturing
processes that can be used to manufacture a crankshaft. Suggest the two (2) processes and which
of these processes preferred and why?
(2 marks)

j) One of the common metal forming processes is extrusion process. Define extrusion
process and briefly describe the types or methods of extrusion.
(4marks)
 CONFIDENTIAL 3 EM/JUN 2015/MEM560
k) What is plastic deformation and describe its importance in metal forming operations.

(3 marks)

l) List three (3) types of hot working processes and also three (3) types of cold
working processes which are commonly available in manufacturing industries.

(3 marks)

m) Distinguish clearly between drop forging and press forging with regards to the
process details, type and quality of products obtained.

(4 marks)

n) With the aids of sketches, describe sheet metal forming processes in making the
body of a two-piece of aluminium drink can.

(6 marks)

o) An ingot measuring 0.5m by 0.5m and length of 2m is rolled into a plate of 1.5m
wide and thickness of 1Omm. Calculate the finished length of the plate.

(5 marks)

p) Hot working process involves plastic deformation above the

recrystallization temperature of the material. Define the recrystallization temperature for a
metal.
(2 marks)

q) Explain the general characteristics of metal forming processes listed below:

i) Rolling ii) Forging iii) Extrusion iv) Drawing

(3 marks)

s) Compare the differences between open die and closed die forging.

(2 marks)
t) Springback occurs in sheetmetal bending due to elastic recovery of the material when
load is removed in the process. Explain two (2) methods to overcome this springback
problem.

(2 marks)

u) Metal forming processes are carried out at various temperatures. What are the
advantages and disadvantages of hot working over cold working of metals?
 CONFIDENTIAL 4 EM/JUN 2015/MEM560
(2 marks)

v) Describe briefly the required properties of an extrusion die and explain why
those properties are required for an extrusion process.

(2 marks)

w) If the force required for piercing process in sheet metal working is 30 kN, calculate
the minimum press capacity required to carry out the job effectively.

(3 marks)

x) Cup drawing is a cold working metal forming process to form a round or flat-
shaped blank into a desired form. For a cup drawing process, derive a formula for
calculating the blank diameter D, for a simple cup-shaped product of diameter d and
depth h, assuming a negligible radius in the bottom corner.

(3 marks)
y) Name the metal forming process that is most suited to the following products:

i) Mild steel bars.

ii) Steel structural section.
iii) Complex aluminium cross-sectional shape.
iv) Aluminium soft drink can.
v) Domestic curtain railing.
vi) Electric cable.
vii) Bullet shell.
viii) Connecting rod.

(4 marks)

z) Describe the sciences of metal forming process. List and explain briefly four (4)
classifications of metal forming.
C01/C2 (6 marks)

1) Explain the influence of flow stress, temperature and strain rate sensitivity in material
behavior during metal forming process.
C03/C6 (4 marks)

2) Distinguish the process of cold, warm and hot forging process.

C02/C4 (3 marks)

3) With the aids of sketches describe the suitable process in order to fabricate 3mm
thickness aluminium cafe chair as illustrate in Figure Q2(d).
C01/C2 (7 marks)
 Figure Q2(d): Aluminium cafe chair

4) Write about bulk deformations processes and four (4) of the basic operation in bulk
deformation.
(6 marks)

5) Justify the suitable process to produce 3mm thickness Aluminium Inner Pot for
Rice Cooker as shown in Figure Q2(b). Based on the sketch, explain the
sequence of processes start from blanking part.
(6 marks)

Figure Q2(b): Aluminium Inner Pot for Rice Cooker (www.1234buv.com)

6) Differentiate between open die forging and close die forging in term of process
and quality of the final product.
(4 marks)

7) Piping and surface cracking are defects associated with extrusion operation. Justify
the countermeasure to avoid the each defect.
(4 marks)

8) Discuss three (3) advantages and three (3) disadvantages of hot working over cold working
processes. (6marks)
9) Name and comment one common defect in sheet metal bending operations.
(3 marks)
10) Explain 'No-draft forging' and give two (2) disadvantages of this process.
(4 marks)

11) Sketch and describe the process to manufacture 0.5 mm thickness aluminum can as
illustrated in Figure Q2(a).
(6
marks)

Figure Q2(a)
12) Explain the influence of flow stress, temperature and strain rate sensitivity in material
behavior during metal forming process.
(2 marks
)
13) Distinguish the process of cold and hot forging process.
(2marks)

14) Intermediate shape of a part is very important in forging process. Illustrate two (2)
intermediate shapes in forging process of a connecting rod for an internal combustion
engine.

(4 marks)

15) Backwards extrusion is more preferable than direct extrusion in aluminum billet
extrusion process. Justify the selected process.
(4 marks)

16) Analyze the importance of controlling process variables such as roll speeds, roll gaps
and temperature in two-high rolling mills operation.

(6 marks)
@

17) Some of the household items available in your home are made from sheet metal
processes. Identify one (1) product available and construct the process or combination
of the processes that are suitable with sheet metal technique(s).
(6marks
)
18) Describe bulk deformation process? Discuss the contribution of hot working process
in metal forming industry.
(4marks)
19) Discuss forging vs extrusion process. Your explanation should include the aspects of
sketch operations, advantages, disadvantages and application with relevant sketches.
(10 arks)
20) Intermediate shape of a part is very important in forging process. Please illustrate two
(2) intermediate shapes in forging process of a connecting rod for an internal
combustion engine.

(4 marks)
21) Please evaluate a condition when backwards extrusion is preferable than direct
extrusion in aluminum billet extrusion process?

(4 marks)
22) Analyze the importance of controlling process variables such as roll speeds, roll gaps
and temperature in two-high rolling mills operation.

(6 marks)

23) Describe the material properties behavior in metal forming operations.

(4 marks)

24) Explain the contribution of hot working process in metal forming industry.

25) Discuss forging vs extrusion process. Your explanation should include the aspects of
sketch operations, advantages, disadvantages and application with relevant sketches.
(10 marks)
26) Two main metal forming processes are forging and extrusion. Distinguish the
differences between the two processes in terms of the principle and product making
process. Give two (2) examples of product produced by each process.
(5marks)