*X10728* Reg. No.

Question Paper Code : X10728

B.E./B.Tech. Degree Examinations, November/December 2020

Fifth/Seventh Semester
Manufacturing Engineering
MF 8791 – Metal Forming Technology
Common to Production Engineering
(Regulations 2017)

Time : Three Hours Maximum : 100 Marks

Answer all questions

Part – A (10×2=20 Marks)

1. What are the principle stresses in metal forming operations ?

2. Differentiate between hot working and cold working operations.

3. Why is intermediate shape important in Forging operations ?

4. Control of the volume of the blank is important in closed-die forging – comment.

5. Why is glass a good lubricating agent in Hot Extrusion process ?

6. How does extrusion differ from rolling and forging ?

7. Explain why normal anisotropy is important in determining the deep drawability

of a material.

8. What causes burrs ? How can they be reduced or eliminated ?

9. What is the significance of Hydroforming process ?

10. What are the limitations of Superplastic forming ?

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Part – B (5×13=65 Marks)

11. a) Discuss the Tresca maximum shear strain energy criteria and its significance
in metal forming applications.

(OR)

b) Explain slip line field theory, also write the assumption in plasticity.

12. a) i) Explain why inner draft angles are larger than outer angles in Forging
operation. (6)

ii) Calculate the forging force for a cylindrical workpiece, made of 1020 steel,
which is 3.5 inches height and 5 inches in diameter and is to be reduced in
height by 30%. The Co-efficient of friction is 0.2. (7)

(OR)

b) A copper strip, 9 in. (228 mm) wide and 1.00 in. (25 mm) thick, is rolled to a
thickness of 0.80 in. (20 mm) in one pass. The roll radius is 12 in. (300 mm)
and the rolls rotate at 100 rpm. Calculate the roll force and the power required
in this operation.

13. a) i) Explain the effect of extrusion ratio, speed and temperature on the Extrusion
force. (6)

ii) Calculate the extrusion force of a round billet which is of 200 mm in diameter
and made of berrylium, and extruded at 1000°C to a diameter of 50 mm. (7)
(OR)

b) Discuss on the Die design and Die materials of Hot Extrusion process.

14. a) i) Explain why springback in Bending depends on yield stress, elastic modulus,
sheet thickness and bend radius. (7)

ii) Identify the material and process variables that influence the punch force
in shearing and explain how each of these affects these force. (6)

(OR)

b) Explain the forming process in which the dies are made up of Polyurethane
membrane with neat diagrams.
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15. a) Compare and contrast the Powder Metallurgy Forging and isothermal Forging
with neat diagrams.
(OR)
b) Discuss in detail the role of CAD/CAM in Metal forming operations.

Part – C (1×15=15 Marks)

16. a) Duplicate the Peen forming process by hammering Aluminum sheets of various
thicknesses with a ball-peen hammer. Describe your observations about the
curvatures produced.
(OR)
b) i) Gears can made by Forging, especially bevel gears. Report a survey of
technical literature and describe the sequence of the manufacturing steps
involved. (10)
ii) Comment on the quality of gear produced by forging when compared to the
gear produced by the conventional casting process. (5)

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