ENGM 445 - MIDTERM EXAM STUDY
QUESTIONS AND ANSWERS GRADED A+
2025/2026
What is the value of the strain-hardening exponent for a metal that will cause the average flow
stress to be 75% of the final flow stress after deformation. - ANS 0.333
A specialized hot working process for making seamless thick-walled tubes using two opposing
rolls is called which one of the following? - ANS Roll piercing
The maximum possible draft in a rolling operation depends on which two of the following
parameters? - ANS Coefficient of friction between roll/work and roll diameter
Which of the following is/are helps in reducing the force in flat rolling? - ANS Use hot rolling,
reduce draft in each pass, and use smaller diameter rolls.
An internal crack that develops as a result of tensile stresses along the centerline of the work
part during extrusion is called which one of the following defects? - ANS Centerburst
Production of tubing is possible in indirect extrusion but not in direct extrusion - ANS False
1 @COPYRIGHT 2026 ALLRIGHTS RESERVED.
,Strain rate sensitivity is greatest under which one of the following situations? - ANS Hot
working
The applied force in an extrusion operation is based on which of the following flow stress
values? - ANS Average flow stress
A single point cutting tool is used for which one of the following operations? - ANS Turning
According to the Merchant equation, an increase in rake angle has which two of the following
effects, all other factors being the same? - ANS Decrease in power requirements and increase
in shear plane angle
At temperatures of hot working, flow stress depends on: - ANS strain rate
Common methods of compensating for springback are which two of the following? -
ANS Bottoming and overbending
In a direct extrusion operation, the portion of the billet that remains in the container and
cannot be forced through the die opening is called - ANS butt
In a sheet metal cutting operation used to produce a flat part with a hole in the center, the part
itself is called a blank, and the scrap piece that is cut out to make the hole is called a slug -
ANS True
In bending of tube stock, special flexible mandrels are usually inserted into the tube prior to
bending to support the walls - ANS True
2 @COPYRIGHT 2026 ALLRIGHTS RESERVED.
, Of the total energy consumed in a machining operation, what proportion of the energy is
converted to heat? - ANS 98%
Springback in sheet-metal bending operation is the result of which one of the following? -
ANS Elastic recovery of the metal
The chip thickness ratio in orthogonal cutting is which one of the following? - ANS Chip
thickness before the cut divided by chip thickness after the cut
The following are measures of feasibility for several proposed cup-drawing operations. Which
three of the operations are likely to be feasible where DR = drawing ratio, r = reduction, t = stock
thickness, and D_b = blank diameter - ANS DR = 1.7, r = 0.35, and t/D_b = 2%
The most frequently used sensor technology for measuring temperatures in machining is which
one of the following? - ANS Thermocouple
What is sticking friction in metal working? - ANS A phenomena that occurs when the friction
stress is greater than the shear flow stress of the metal and when the work surface adheres to
the surface of the tool rather than slides against, generally associated with hot working
When using the orthogonal cutting model to approximate a turning operation, the chip
thickness before the cut corresponds to which one of the following cutting conditions in
turning? - ANS Feed
Which one of the following processes uses a thick rubber pad to form sheet metal over a
positive form block? - ANS Guerin process
Which one of the four types of chip is most likely in a turning operation conducted at low
cutting speed on a brittle working material? - ANS Discontinuous
3 @COPYRIGHT 2026 ALLRIGHTS RESERVED.
QUESTIONS AND ANSWERS GRADED A+
2025/2026
What is the value of the strain-hardening exponent for a metal that will cause the average flow
stress to be 75% of the final flow stress after deformation. - ANS 0.333
A specialized hot working process for making seamless thick-walled tubes using two opposing
rolls is called which one of the following? - ANS Roll piercing
The maximum possible draft in a rolling operation depends on which two of the following
parameters? - ANS Coefficient of friction between roll/work and roll diameter
Which of the following is/are helps in reducing the force in flat rolling? - ANS Use hot rolling,
reduce draft in each pass, and use smaller diameter rolls.
An internal crack that develops as a result of tensile stresses along the centerline of the work
part during extrusion is called which one of the following defects? - ANS Centerburst
Production of tubing is possible in indirect extrusion but not in direct extrusion - ANS False
1 @COPYRIGHT 2026 ALLRIGHTS RESERVED.
,Strain rate sensitivity is greatest under which one of the following situations? - ANS Hot
working
The applied force in an extrusion operation is based on which of the following flow stress
values? - ANS Average flow stress
A single point cutting tool is used for which one of the following operations? - ANS Turning
According to the Merchant equation, an increase in rake angle has which two of the following
effects, all other factors being the same? - ANS Decrease in power requirements and increase
in shear plane angle
At temperatures of hot working, flow stress depends on: - ANS strain rate
Common methods of compensating for springback are which two of the following? -
ANS Bottoming and overbending
In a direct extrusion operation, the portion of the billet that remains in the container and
cannot be forced through the die opening is called - ANS butt
In a sheet metal cutting operation used to produce a flat part with a hole in the center, the part
itself is called a blank, and the scrap piece that is cut out to make the hole is called a slug -
ANS True
In bending of tube stock, special flexible mandrels are usually inserted into the tube prior to
bending to support the walls - ANS True
2 @COPYRIGHT 2026 ALLRIGHTS RESERVED.
, Of the total energy consumed in a machining operation, what proportion of the energy is
converted to heat? - ANS 98%
Springback in sheet-metal bending operation is the result of which one of the following? -
ANS Elastic recovery of the metal
The chip thickness ratio in orthogonal cutting is which one of the following? - ANS Chip
thickness before the cut divided by chip thickness after the cut
The following are measures of feasibility for several proposed cup-drawing operations. Which
three of the operations are likely to be feasible where DR = drawing ratio, r = reduction, t = stock
thickness, and D_b = blank diameter - ANS DR = 1.7, r = 0.35, and t/D_b = 2%
The most frequently used sensor technology for measuring temperatures in machining is which
one of the following? - ANS Thermocouple
What is sticking friction in metal working? - ANS A phenomena that occurs when the friction
stress is greater than the shear flow stress of the metal and when the work surface adheres to
the surface of the tool rather than slides against, generally associated with hot working
When using the orthogonal cutting model to approximate a turning operation, the chip
thickness before the cut corresponds to which one of the following cutting conditions in
turning? - ANS Feed
Which one of the following processes uses a thick rubber pad to form sheet metal over a
positive form block? - ANS Guerin process
Which one of the four types of chip is most likely in a turning operation conducted at low
cutting speed on a brittle working material? - ANS Discontinuous
3 @COPYRIGHT 2026 ALLRIGHTS RESERVED.
