MAE 364 Exam 2 Review UPDATED ACTUAL
QUESTIONS AND CORRECT ANSWERS
Metal Forming - CORRECT ANSWER Large group of manufacturing processes in
which plastic deformation is used to change the shape of the metal workpieces
Tool used in metal forming - CORRECT ANSWER die
-applies stresses that exceed the yield strength
Stresses used in metal forming - CORRECT ANSWER Usually, compressive
ex:
rolling
forging
extrusion
Desirable material properties for forming - CORRECT ANSWER -Low yield strength
-High ductility
-These properties are affected by temperature
Bulk Deformation processes - CORRECT ANSWER rolling, forging, extrusion, wire
and bar drawing
Bulk Deformation - CORRECT ANSWER -Characterized by significant deformations
and massive shape changes
-Low surface area to volume ratio
Sheet forming - CORRECT ANSWER -Performed on metal sheets, strips, and coils
,-High surface area to volume ratio
Sheet Forming Processes - CORRECT ANSWER Bending, Deep drawing, shearing
Temperature relationship to metal forming - CORRECT ANSWER Higher
temperatures = Strength and strain hardening = lower forces and power
Higher temperature = increased ductility = greater plastic deformation of metal
Temperature ranges of metal forming - CORRECT ANSWER Cold working: Room
temperature or slightly above
Warm working: 0.3Tm to 0.5Tm
Hot working: 0.5Tm to 0.75Tm
Effect of friction on metal forming - CORRECT ANSWER 1. Reduced metal flow
2. Increased forces and power
3. Faster tool wear
How to reduce friction - CORRECT ANSWER apply lubrication to tool-work
interfaces
Effect of lubrication on metal forming - CORRECT ANSWER a. Reduce sticking,
forces, power, tool wear
b. Better surface finish
c. Removes heat from the tooling
Metal Forming Processes - Rolling - CORRECT ANSWER Deformation process in
which work thickness is reduced by compressive forces exerted by two opposing rolls.
, Two main functions of opposing rolls - CORRECT ANSWER 1. Pull the work into the
gap between them by friction between the work part and rolls
2. Simultaneously squeeze the work to reduce its cross-section
Intermediate shapes for rolling - CORRECT ANSWER Bloom -> structural shapes
Slab -> plates and sheets
Billet -> Bars and rods
Flat rolling analysis - CORRECT ANSWER The rolls contact the workpart along an
arc defined by the angle θ.
Each roll has radius R, and its rotational speed gives it a surface velocity vr.
Draft - CORRECT ANSWER the amount of thickness reduction in rolling
can also be expressed as a fraction of the starting stock thickness, called reduction, r
Power required to drive each roll - CORRECT ANSWER Product of torque and
angular velocity (2πN)
P = 2πNFL (for two rolls)
Friction during rolling - CORRECT ANSWER Too much friction can be detrimental
Friction on entrance side of rolls (before the no-slip point) is greater than the friction force at
the exit
Rolling coefficent of friction parameters - CORRECT ANSWER a. Lubrication
b. Work material
c. Working temperature
Extreme operating conditions in rolling - CORRECT ANSWER a. Large forces
QUESTIONS AND CORRECT ANSWERS
Metal Forming - CORRECT ANSWER Large group of manufacturing processes in
which plastic deformation is used to change the shape of the metal workpieces
Tool used in metal forming - CORRECT ANSWER die
-applies stresses that exceed the yield strength
Stresses used in metal forming - CORRECT ANSWER Usually, compressive
ex:
rolling
forging
extrusion
Desirable material properties for forming - CORRECT ANSWER -Low yield strength
-High ductility
-These properties are affected by temperature
Bulk Deformation processes - CORRECT ANSWER rolling, forging, extrusion, wire
and bar drawing
Bulk Deformation - CORRECT ANSWER -Characterized by significant deformations
and massive shape changes
-Low surface area to volume ratio
Sheet forming - CORRECT ANSWER -Performed on metal sheets, strips, and coils
,-High surface area to volume ratio
Sheet Forming Processes - CORRECT ANSWER Bending, Deep drawing, shearing
Temperature relationship to metal forming - CORRECT ANSWER Higher
temperatures = Strength and strain hardening = lower forces and power
Higher temperature = increased ductility = greater plastic deformation of metal
Temperature ranges of metal forming - CORRECT ANSWER Cold working: Room
temperature or slightly above
Warm working: 0.3Tm to 0.5Tm
Hot working: 0.5Tm to 0.75Tm
Effect of friction on metal forming - CORRECT ANSWER 1. Reduced metal flow
2. Increased forces and power
3. Faster tool wear
How to reduce friction - CORRECT ANSWER apply lubrication to tool-work
interfaces
Effect of lubrication on metal forming - CORRECT ANSWER a. Reduce sticking,
forces, power, tool wear
b. Better surface finish
c. Removes heat from the tooling
Metal Forming Processes - Rolling - CORRECT ANSWER Deformation process in
which work thickness is reduced by compressive forces exerted by two opposing rolls.
, Two main functions of opposing rolls - CORRECT ANSWER 1. Pull the work into the
gap between them by friction between the work part and rolls
2. Simultaneously squeeze the work to reduce its cross-section
Intermediate shapes for rolling - CORRECT ANSWER Bloom -> structural shapes
Slab -> plates and sheets
Billet -> Bars and rods
Flat rolling analysis - CORRECT ANSWER The rolls contact the workpart along an
arc defined by the angle θ.
Each roll has radius R, and its rotational speed gives it a surface velocity vr.
Draft - CORRECT ANSWER the amount of thickness reduction in rolling
can also be expressed as a fraction of the starting stock thickness, called reduction, r
Power required to drive each roll - CORRECT ANSWER Product of torque and
angular velocity (2πN)
P = 2πNFL (for two rolls)
Friction during rolling - CORRECT ANSWER Too much friction can be detrimental
Friction on entrance side of rolls (before the no-slip point) is greater than the friction force at
the exit
Rolling coefficent of friction parameters - CORRECT ANSWER a. Lubrication
b. Work material
c. Working temperature
Extreme operating conditions in rolling - CORRECT ANSWER a. Large forces
