MAE 364 Review Exam QUESTIONS AND
CORRECT ANSWERS
Generally, what is the definition of metal forming? - CORRECT ANSWER Large
group of manufacturing processes in which plastic deformation is used to change the shape of
the metal workpieces.
What types of stress do materials experience during metal forming? - CORRECT
ANSWER Stresses to plastically deform the metal are usually compressive. However
some forming processes stretch the metal(Tensile Stresses). Others bend the Metal(Tensile
and Compressive Stresses). Still other apply Shear Stresses.
What are the desirable material properties desirable for metal forming? - CORRECT
ANSWER Low Yield Strength and High Ductility.
What are the two metal forming categories?
a) What is the ratio used to differentiate between the categories?
b) What are the main processes in each category? - CORRECT ANSWER Bulk
Deformation and Sheet Metal Working Processes.
a) Surface Area to Volume Ratios. (Low surface area to Volume ratio for 'Bulk')
b)
Bulk: Rolling, Forging, Extrusion, and Wire and Bar Drawing.
Sheet Metal Working: Bending, Deep Drawing, Shearing: punch first contacting, after
cutting.
What are the benefits of increased temperature in metal forming? - CORRECT
ANSWER Strength and strain hardening are reduced at higher temperature, which
results in lower forces and power during forming. Ductility increased at higher temperatures,
which allows greater plastic deformation of the metal.
, How does friction affect metal forming processes? - CORRECT ANSWER In most
metal forming processes, friction is undesirable.
Metal flow is reduced. Forces and power are increased. Tools wear faster.
What are the benefits of lubrication in metal forming processes? - CORRECT
ANSWER Reduce Contact Pressure. Minimize metal-to-metal contact.
What are the descriptions of the main bulk metal forming processes category?
a) Rolling
b) Forging
c) Extrusion
d) Drawing - CORRECT ANSWER a) Slab or plate is squeezed between opposing
rolls.
b) Work is squeezed and shaped between opposing dies.
c) Work is squeezed through a die opening, thereby taking the shape of the opening
d) Diameter of wire or bar is reduced by pulling it through a die opening.
In reference to the rolling bulk deformation process:
a) What are the two main functions of the opposing rolls?
b) What are the three intermediate shapes for starting materials?
c) In Flat rolling analysis:
i. What is the draft?
1. How is draft calculated?
2. What is another way to express draft?
3. How is the max amount of draft that can be accomplished calculated?
ii. How is the true strain experienced by work in rolling calculated?
CORRECT ANSWERS
Generally, what is the definition of metal forming? - CORRECT ANSWER Large
group of manufacturing processes in which plastic deformation is used to change the shape of
the metal workpieces.
What types of stress do materials experience during metal forming? - CORRECT
ANSWER Stresses to plastically deform the metal are usually compressive. However
some forming processes stretch the metal(Tensile Stresses). Others bend the Metal(Tensile
and Compressive Stresses). Still other apply Shear Stresses.
What are the desirable material properties desirable for metal forming? - CORRECT
ANSWER Low Yield Strength and High Ductility.
What are the two metal forming categories?
a) What is the ratio used to differentiate between the categories?
b) What are the main processes in each category? - CORRECT ANSWER Bulk
Deformation and Sheet Metal Working Processes.
a) Surface Area to Volume Ratios. (Low surface area to Volume ratio for 'Bulk')
b)
Bulk: Rolling, Forging, Extrusion, and Wire and Bar Drawing.
Sheet Metal Working: Bending, Deep Drawing, Shearing: punch first contacting, after
cutting.
What are the benefits of increased temperature in metal forming? - CORRECT
ANSWER Strength and strain hardening are reduced at higher temperature, which
results in lower forces and power during forming. Ductility increased at higher temperatures,
which allows greater plastic deformation of the metal.
, How does friction affect metal forming processes? - CORRECT ANSWER In most
metal forming processes, friction is undesirable.
Metal flow is reduced. Forces and power are increased. Tools wear faster.
What are the benefits of lubrication in metal forming processes? - CORRECT
ANSWER Reduce Contact Pressure. Minimize metal-to-metal contact.
What are the descriptions of the main bulk metal forming processes category?
a) Rolling
b) Forging
c) Extrusion
d) Drawing - CORRECT ANSWER a) Slab or plate is squeezed between opposing
rolls.
b) Work is squeezed and shaped between opposing dies.
c) Work is squeezed through a die opening, thereby taking the shape of the opening
d) Diameter of wire or bar is reduced by pulling it through a die opening.
In reference to the rolling bulk deformation process:
a) What are the two main functions of the opposing rolls?
b) What are the three intermediate shapes for starting materials?
c) In Flat rolling analysis:
i. What is the draft?
1. How is draft calculated?
2. What is another way to express draft?
3. How is the max amount of draft that can be accomplished calculated?
ii. How is the true strain experienced by work in rolling calculated?
