Forging Processes Test - Section A: Knowledge and Understanding

Forging in the context of engineering is defined as:

• A process of shaping metal using compressive forces.

• A method of joining two metals by melting them together.

• A technique of removing material from a workpiece using a cutting tool.

• A process of coating a metal surface with another metal.

For each forging method below, give one example of a product made using it.

• Drop Forging: Wrenches or crankshafts; Press Forging: Aircraft landing gear; Upset Forging: Bolt heads

• Drop Forging: Bicycle frames; Press Forging: Paper clips; Upset Forging: Springs

• Drop Forging: Gears; Press Forging: Nails; Upset Forging: Chains

• Drop Forging: Screws; Press Forging: Washers; Upset Forging: Pipes

Drop forging is suitable for small to medium-sized shapes because:

• it allows precise shaping and good mechanical properties for these sizes.

• it is only economical for very large shapes.

• it cannot produce strong components.

• it is mainly used for sheet metal work.

Press forging is used for parts like aircraft landing gear because:

• it produces strong and tough components needed for high-stress applications.

• it is the cheapest method for making all metal parts.

• it requires no specialized equipment or high pressure.

• it is only suitable for small, decorative items.

A company needs to produce bolt heads in large quantities. Which forging method should they use and why?

• Drop forging, because it is suitable for mass production and produces consistent shapes.

• Hand forging, because it is faster for large quantities.

• Press forging, because it is only used for small batches.

• Upset forging, because it is not suitable for bolt heads.

The most appropriate forging method for producing engine cam shafts that require good dimensional accuracy is:

• Open die forging

• Closed die forging

• Roll forging

• Upset forging

Drop forging and press forging can be compared in terms of force applied and product characteristics. Which of the following statements is correct?

• Drop forging uses sudden impact force and produces tougher products, while press forging uses gradual pressure and results in more precise shapes.

• Drop forging uses gradual pressure and produces more precise shapes, while press forging uses sudden impact force and results in tougher products.

• Both drop forging and press forging use the same force application and produce identical product characteristics.

• Drop forging and press forging both use gradual pressure but differ only in the type of metal used.

Forging is defined as:

• A process of shaping metal by applying compressive forces.

• A process of joining two metals by melting them together.

• A method of removing material from a workpiece using a cutting tool.

• A process of coating a metal surface with another metal.

Examples of products.

• Drop Forging: Engine cam shaft, Spanner, Wrench Press Forging: Aircraft landing gear, Large structural parts Upset Forging: Bolt head, Rivet, Valve

• Drop Forging: Plastic bottles, Paper clips, Erasers Press Forging: Wooden chairs, Glass bottles Upset Forging: Rubber bands, Plastic spoons, Paper cups

• Drop Forging: Bicycle tires, Wooden pencils, Plastic bags Press Forging: Cardboard boxes, Cotton shirts Upset Forging: Paper plates, Foam cups, Plastic straws

• Drop Forging: Ceramic mugs, Glass jars, Leather belts Press Forging: Woolen scarves, Silk ribbons Upset Forging: Wooden spoons, Clay pots, Plastic lids

Why drop forging is suitable for small to medium-sized shapes?

• High-speed hammering allows for quick shaping. Provides good dimensional accuracy and strength for smaller components.

• It is only used for making large and complex parts.

• Drop forging is not suitable for any metal components.

• It is mainly used for plastic and ceramic materials.