WorksheetsUB MAE 364 Test 2 Review
Total questions: 40
Worksheet time: 32mins
What is the definition of metal forming
Metal forming is the process of creating metal sculptures through welding and soldering techniques
A manufacturing process by which plastic deformation occurs to change the shape of the metal workpiece
Metal forming involves the chemical transformation of metals into new compounds through oxidation and reduction reactions
Metal forming refers to the process of shaping metals using high-intensity lasers
Select all that apply: What types of stress do materials experience during metal forming?
Tensile Stresses
Compressive Stresses
Friction Forces
Shear Stress
What are the desirable material properties for metal forming?
Low ductility and low yield point
High porosity and low hardness
High ductility and low yield point
Low tensile strength and high elasticity
Select the two metal forming categories
Thermal
Bulk deformation
Mechanical forming
Sheet metal forming
What is the ratio used to differentiate between metal forming categories?
Length to thickness- High for bulk, low for sheet metal
Area to volume - Low for bulk, high for sheet metal
Viscosity to density- Low for bulk, high for sheet metal
Elasticity to strength- High for bulk, low for sheet metal
Match the following
Sheet metal forming process
Bending
Bulk Deformation
Wire and Bar Drawing
Sheet metal forming process
Shearing or Punching
Bulk Deformation
Forging
Rolling
Bulk Deformation
Select all that apply: What are the benefits of increasing the temperature in metal forming?
Increased ductility - greater deformation possible
Reduced strain and strength hardening - lower forces required
Reduced ductility - greater deformation possible
Lower tool wear and less maintenance
Match the following
Cold working
Room temperature
Warm working
0.3 Tm - 0.5 Tm
Hot Working
0.5 Tm - 0.75 Tm
Select all that apply: How does friction affect the metal forming process
(Larger friction effects occur at higher temperature)
Metal flow reduced
Required force and power increases
Reduces energy required
Increased wear and maintenance
What are the benefits of lubrication in metal forming?
Increases maintenance and wear
Reduced surface quality
Reduces friction, wear, heat generation
Improved surface quality
In rolling bilk deformation processes, what are the 2 main functions of the opposing rolls?
Insulation and cooling the work piece
Pull the work into gap, reduce cross section
Reduce vibrations and enhance material flow
Apply magnetic field, control shape
Match the following
Rolling
Deforming metal by passing between rolls
Forging
Shaping metal by compressive forces
Extrusion
Forcing metal through a die
Drawing
Pulling metal through a die
Match the following starting shapes to intermediate steps for rolling bulk deformation cases:
Bloom
Structural shapes, ie beams, rails
Slab
Sheets, coils
Billet
Bars, rods
What is the draft? (a) in thickness of the workpiece?
For rolling what is the no slip point?
Where the material velocity exceeds the roll velocity
Where material velocity matches the roll velocity
Where the material velocity is zero
During rolling can friction have a positive and negative aspect?
Yes
No
Select all that apply: What are desirable material properties for rolling?
Ductility
Strength
Wear resistance
Rigidity
Select all that apply: What are some common rolling defects?
Wavy edges - Caused by bending in rolls
Coloration variation - caused by surface contamination
Edge and internal cracks - caused by low ductility
Alligatoring - caused by defects in ingot casting
What is open die forging?
Metal is formed in a sealed chamber
Shaping of metal between flat dies
Metal is heated and shaped
What are the three ways to classify bulk deformation processes
Temperature
Cooling
Workpiece movement
Die design
What is impression die forging?
Die with a cavity that is imparted to a workpart
When metal is forged without the use of a mold or die
When an impression is made
When metal is forged by hand
How does flash influence impression die forging
It doesn't
Increases material flow and accuracy
Metal flow decreased
Friction resist metal flow into gap
Select all that apply: What are the advantages of impression die forging
Higher production rates
High waste, low strength
Less waste, greater strength
Favorable grain orientation
What is a limitation of impression die forging?
High energy required
Not capable of close tolerance
High costs per part
Limited tool life
What are the effects of a small die angle
High friction - more force required
No effects
Low friction - more force required
Low energy required
Select all that apply: Effects of a large die angle?
Low energy consumption
Increased metal lateral flow
Reduced die wear
Decreased metal flow
For wire and rod drawing bulk deformation, what stress is experienced?
Compressive
Tensile
Shear
Negligible
Select two: What is the difference between wire and bar drawing?
Wire - reduce cross section
Bar - reduce cross section
Wire - reduce diameter
Bar - reduce diameter
How is the starting end of material prepared for drawing? It is chambered or Po (a) ed to ease entry.
(Write the whole word)
Match the advantages and disadvantages of machining
High variety of materials
Advantage
High precision
Advantage
Surface finish
Advantage
Slow production rate
Disadvantage
High waste
Disadvantage
A tool (a) material
Match the following
Finishing cut
Completes part geometry
Rough cut
Removes large amount of material
Cutting conditions
Speed, feed, depth
Material removal rate
How much material removed per unit time
Select all that apply: What cutting conditions change the type of chip produced
Cutting speed
Material
Feed rate
Depth of cut
Match the following pairs of forces in machining
Cutting force
Thrust force
Normal force to friction
Friction force
Shear force
Normal force to shear
What are two measurable forces?
Cutting force
Shear force
Thrust force
Normal forces
What is rapid prototyping (RP)?
Traditional manufacturing
Temporary prototypes
Manufacturing on large scales
Quickly creating physical prototypes from digital designs
3 Types of starting material for additive manufacturing
Liquid
Powder
Solid
Gasses
Select all that apply: Limitations of additive manufacturing
Materials
Complex geometry
Poor surface finish
Dimensional accuracy
What role does temperature play in the metal extrusion process?
Higher temperatures can weaken the metal
Temperature has no effect on metal extrusion
Lower temperatures increase material strength
Higher temperatures reduce the force required for extrusion
How does the grain size of a metal affect its formability?
Smaller grains enhance formability
Larger grains enhance formability
Grain size has no impact on formability
Only the grain shape matters, not the size
