EMAE 160 FINAL REVIEW CWRU -
METAL FORMING EXAM QUESTIONS
AND ANSWERS
Does the flash produced in impression die forging serve a useful purpose? Is it
desirable? Why? - ANSWER-Yes. This flash cools quicker than the part in the cavity
and thus keeps the rest of the metal fixed where it needs to be.
Define spring-back in sheet metal bending. - ANSWER-When a bent piece of sheet
metal bends back a bit after releasing the force that bent it in the first place.
Name the three types of forging processes. - ANSWER-Hydraulic, mechanical,
impact.
Explain the difference between a mechanical press and a hydraulic press for forging.
- ANSWER-Hydraulic- Slow with a constant force.
Mechanical- Quick bursts of force.
Explain the differences between cold-rolled and hot-rolled steels. - ANSWER-Cold-
rolled has a better surface, tolerance, and mechanical properties.
Hot-rolled takes place above the recrystallization temperature.
Is forging always done in a vertical direction? - ANSWER-No (absolutely not you
imbecile).
How is a soda can made? - ANSWER-Deep drawing
How is high pressure tubing made? - ANSWER-Extrusion
How is low pressure pipe made? - ANSWER-Roll formed
What is the most common metal used in extrusion? - ANSWER-Aluminium
How are the undercarriage tubes in the automotive industry created? - ANSWER-
Hydroforming
House gutters are manufactured using what process? - ANSWER-Roll forming
What is metal spinning? - ANSWER-When a metal disk or tube rotates while a
stationary metal roller pushes the disk onto the mandrel to make it a symmetrical
part. Constant wall thickness.
What are the differences between metal spinning, shear spinning, flow forming? -
ANSWER-Shear spinning has reduction in wall thickness. Flow forming has
reduction in wall thickness, and is for extremely accurate, long, cylindrical parts.
METAL FORMING EXAM QUESTIONS
AND ANSWERS
Does the flash produced in impression die forging serve a useful purpose? Is it
desirable? Why? - ANSWER-Yes. This flash cools quicker than the part in the cavity
and thus keeps the rest of the metal fixed where it needs to be.
Define spring-back in sheet metal bending. - ANSWER-When a bent piece of sheet
metal bends back a bit after releasing the force that bent it in the first place.
Name the three types of forging processes. - ANSWER-Hydraulic, mechanical,
impact.
Explain the difference between a mechanical press and a hydraulic press for forging.
- ANSWER-Hydraulic- Slow with a constant force.
Mechanical- Quick bursts of force.
Explain the differences between cold-rolled and hot-rolled steels. - ANSWER-Cold-
rolled has a better surface, tolerance, and mechanical properties.
Hot-rolled takes place above the recrystallization temperature.
Is forging always done in a vertical direction? - ANSWER-No (absolutely not you
imbecile).
How is a soda can made? - ANSWER-Deep drawing
How is high pressure tubing made? - ANSWER-Extrusion
How is low pressure pipe made? - ANSWER-Roll formed
What is the most common metal used in extrusion? - ANSWER-Aluminium
How are the undercarriage tubes in the automotive industry created? - ANSWER-
Hydroforming
House gutters are manufactured using what process? - ANSWER-Roll forming
What is metal spinning? - ANSWER-When a metal disk or tube rotates while a
stationary metal roller pushes the disk onto the mandrel to make it a symmetrical
part. Constant wall thickness.
What are the differences between metal spinning, shear spinning, flow forming? -
ANSWER-Shear spinning has reduction in wall thickness. Flow forming has
reduction in wall thickness, and is for extremely accurate, long, cylindrical parts.
