Manufacturing Processes Exam #1
questions with answers
Direct Extrusion - correct answer ✔✔❖Solid ram drives entire billet to and through a stationary die
❖Must provide power to overcome friction
Indirect Extrusion - correct answer ✔✔A hollow ram pushes the die back through a stationary, confined
billet
Extrusion Process - correct answer ✔✔Metal is compressed and forced to flow through a shaped die to
form a product with a constant cross section
What type of working can extrusion process be performed? - correct answer ✔✔Hot or cold working,
but hot working is commonly used
Blooms - correct answer ✔✔Square or rectangular cross section
Billets - correct answer ✔✔Usually smaller than a bloom, square or circular cross section
Slabs - correct answer ✔✔Typically rectangular, width > 2X thickness
open-die hammer forging - correct answer ✔✔the same type of forging done by the blacksmith of old,
but massive mechanical equipment is now used to impart the repeated blows (used by a mechanical
hammer)
closed-die (impression die) forging - correct answer ✔✔• Dies are shaped to control the flow of metal
• Upper piece attaches to the hammer and the lower piece to the anvil
• Metal flows and completely fills the die
, what happens in closed-die? - correct answer ✔✔• During forging, excess metal may squeeze out of the
die. This issue is called a flash
What are some important design details in hammer forging? - correct answer ✔✔❖Number of
intermediate steps
❖Shape of each step
❖Amount of metal to fill the die
❖Dimensions of flash at each step
❖Good dimensional accuracy
What is the significance in lubrication? - correct answer ✔✔reduces friction and act as a heat barrier
Bulk Forming Processes - correct answer ✔✔❖Rolling
❖Forging
❖Extrusion
❖Wire, rod, and tube drawing
❖Piercing
❖Squeezing processes
❖Cold forming, cold forging, and impact extrusion
Rolling Process - correct answer ✔✔Operations reduce material's thickness or change cross section
through compressive forces
Categories of Sheet Metal Forming - correct answer ✔✔❖Shearing
❖Bending
❖Drawing
What does sheet metal processes involve? - correct answer ✔✔Plane stress loadings and lower forces
than bulk forming
questions with answers
Direct Extrusion - correct answer ✔✔❖Solid ram drives entire billet to and through a stationary die
❖Must provide power to overcome friction
Indirect Extrusion - correct answer ✔✔A hollow ram pushes the die back through a stationary, confined
billet
Extrusion Process - correct answer ✔✔Metal is compressed and forced to flow through a shaped die to
form a product with a constant cross section
What type of working can extrusion process be performed? - correct answer ✔✔Hot or cold working,
but hot working is commonly used
Blooms - correct answer ✔✔Square or rectangular cross section
Billets - correct answer ✔✔Usually smaller than a bloom, square or circular cross section
Slabs - correct answer ✔✔Typically rectangular, width > 2X thickness
open-die hammer forging - correct answer ✔✔the same type of forging done by the blacksmith of old,
but massive mechanical equipment is now used to impart the repeated blows (used by a mechanical
hammer)
closed-die (impression die) forging - correct answer ✔✔• Dies are shaped to control the flow of metal
• Upper piece attaches to the hammer and the lower piece to the anvil
• Metal flows and completely fills the die
, what happens in closed-die? - correct answer ✔✔• During forging, excess metal may squeeze out of the
die. This issue is called a flash
What are some important design details in hammer forging? - correct answer ✔✔❖Number of
intermediate steps
❖Shape of each step
❖Amount of metal to fill the die
❖Dimensions of flash at each step
❖Good dimensional accuracy
What is the significance in lubrication? - correct answer ✔✔reduces friction and act as a heat barrier
Bulk Forming Processes - correct answer ✔✔❖Rolling
❖Forging
❖Extrusion
❖Wire, rod, and tube drawing
❖Piercing
❖Squeezing processes
❖Cold forming, cold forging, and impact extrusion
Rolling Process - correct answer ✔✔Operations reduce material's thickness or change cross section
through compressive forces
Categories of Sheet Metal Forming - correct answer ✔✔❖Shearing
❖Bending
❖Drawing
What does sheet metal processes involve? - correct answer ✔✔Plane stress loadings and lower forces
than bulk forming
