Question: Describe the following types of rolling arrangements:

• Three high rolls

• Four high rolls
• Cluster rolls
• Planetary rolls
Answer:
• Three-high rolls: Three rolls placed one above the other. The workpiece
passes through the lower and middle roll in one direction, then reversed through
the upper and middle roll. Advantage: continuous rolling without reversing rolls.
• Four-high rolls: Two small working rolls supported by two larger backup
rolls. Advantage: reduces roll deflection, used for thinner sheets.
• Cluster rolls: Consist of multiple small diameter rolls backed by
larger rolls. Used for rolling very thin sheets with high precision.
• Planetary rolls: Several small rolls (planets) arranged around a large
backup roll. Large thickness reduction achieved in a single pass.

Question: Describe cold and hot rolling. What is the advantage(s)/disadvantage(s)

of each?
Answer:
• Hot rolling: Rolling performed above recrystallization temperature.
◦ Advantages: Large deformation possible, eliminates defects, less force
required.
◦ Disadvantages: Poor surface finish, dimensional inaccuracy, scale
formation.
• Cold rolling: Rolling below recrystallization temperature.
◦ Advantages: Better surface finish, closer tolerances, strain hardening
improves strength.
◦ Disadvantages: Higher forces required, limited deformation, residual
stresses.

Question: Explain the reason why water is not able to chill the workpiece in
rolling operation.
Answer:
In rolling, the workpiece surface is in direct contact with hot rolls, and
deformation generates high heat at the interface. Water evaporates instantly due to
high temperatures and cannot penetrate effectively to cool the workpiece. Cooling
is more effective for rolls than for the workpiece.

Question: What are the advantages of forging?

• Increased streanth and durability of products
• Superior Strength
• Enhanced Metallurgical Properties
• Customization
• Fine Grain Structure
• Reduced Material Waste
• Cost-Effective for High Volume
• Versatility
• Enhanced Grain Flow
• Consistency and Reproducibility
• High-Temperature Performance
• Improved Fatigue Resistance
• Longer Lifespan
• Reduced Machining Needs
• Suitable for Critical Applications
• Environmentally Friendly

Question: Describe the classification of forging based on:

• Types of die
• Temperature of workpiece
• Types of machines employed
Answer:
• Types of die: Open-die forging, Closed-die forging, Precision die
forging.
• Temperature of workpiece: Hot forging, Warm forging, Cold forging.
• Types of machines employed: Hammer forging, Press forging, Upset
forging machines.

Question: What is the difference between closed die forging and precision die
forging?
Answer:
Closed die forging and precision forging are both metal forming processes, but they
differ in
terms of precision and application. Closed die forging involves shaping heated
metal between
dies to create parts, offering good accuracy but with some variability in
tolerances and surface
finishes, making it suitable for various industries. While,
Precision forging, on the other hand, employs more controlled, computer-assisted
techniques, resulting in exceptionally tight tolerances and superior surface
finishes, making it
ideal for specialized applications, particularly in aerospace and other sectors
requiring the
highest levels of precision and quality.

Question: What is extrusion in metal forming? Describe the three main types of
extrusion.
Answer:
Extrusion in metal forming is a manufacturing process that involves forcing a metal
billet or
workpiece through a shaped die to produce a product with a consistent cross-
sectional profile.
This process is commonly used to create objects with a constant cross-section, such
as rods,
tubes, and various other shapes.
Types of extrusion
Direct extrusion : In direct extrusion, also known as forward extrusion, the metal
billet is placed
in the extrusion chamber, and a ram or piston applies force directly onto the
billet. This force
pushes the billet through the die, creating the desired shape. Direct extrusion is
a common method
for producing long continuous shapes like rods, bars, and pipes. It's
straightforward and suitable
for materials that can withstand the compressive forces involved.
Indirect Extrusion: Indirect extrusion, also called backward extrusion, is a
variation where the
die is located at the end of the ram or piston, and the metal billet remains
stationary. As the ram
moves into the billet, the metal flows around it and takes on the shape of the die.
Indirect extrusion
is useful when you want to maintain the purity and cleanliness of the product since
the metal
doesn’t come into contact with the chamber walls. It’s often used for materials
that are sensitive
to contamination, like certain alloys.
Impact Extrusion: Impact extrusion is a different extrusion method that involves
using a punch
to strike a metal blank or slug placed inside a die cavity. The force of the impact
deforms the metal
and forces it to take the shape of the die. Impact extrusion is commonly used to
produce small,
hollow, and intricate shapes, such as metal containers, like aerosol cans and
collapsible tubes.
It's a cost-effective method for high-volume production of these types of products.
7. Describe any three types of tubing drawing
Tube drawing: a process in which a larger diameter tube is shrunk into a smaller
diameter
tube by drawing through a duct , process often carried out after hot working
Types
Tube sinking: a tube is drawn through a die to reduce its internal and external
diameter
without any internal support, the surface finish in this case is uneven.
Fixed plug: in this case a a plug or mandrel is provided inside the tube, the
mandrel provided
is fixed in its position, provides better internal surface finish.
Floating plug: here a floating mandrel is provided inside the tube, its position is
controlled by
the tangential and normal forces of the tubes contact surfaces.m
Moving mandrel: here both tube and mandrel are moved to gether to provide high
quality
tubing with very good dimensional accuracy.

Question: Describe four major regimes of lubrication

Thick film:
Description: Here the two surfaces are separated completely by thick film of
lubricant,
Condition: High speed and high viscosity lubricants, the lubricants become trapped
between the die-workpiece interface.
Effects: dull, granny surface appearance on the workpiece.
Thin film:
Condition: as the load between the die and workpiece increases, or when speed
increases and viscosity of working fluid decreases, the lubricant film becomes
thinner.
Effects: friction is raised resulting in slight wear.
Mixed lubrication:
Condition: here a significant portion of load is carried by physical contact
between
asperities of the two contacting surfaces, the rest of the load is carried by
pressurized fluid
in pockets (valleys between the asperities)
Effects: increased friction and wear, surface finish alterations, heat generation
and
increased risk of scuffing.
Boundary lubrication
Description: here load is supported by the contacting surfaces that are covered by
a boundary
film lubricant ( a layer that can be as thin as a single molecule.
Lubricant film is attracted to the metal surface preventing metal- metal contact
Effects: film can break down as a result of heat generation from sliding surfaces
or being rubbed
off by the sliding surfaces, resulting in wear and possible scoring of surfaces.
9. What are the functions of metal working fluids?
• Reduction of friction, thus reducing force and energy requirements and any rise
in
temperature.
• Reduction of wear, thus reducing seizure and galling
• Improve material flow in tools, dies, and molds
• Act as a release or parting agent, a substance that helps in the removal or
ejection of
parts from dies and molds
• Act as a thermal barrier between the work piece and its tool and die surfaces,
thus
preventing work piece cooling in hot-working processes.
10. Describe four types of solid lubricants.
• Graphite
• Molybdenum Disulfide
• Glasses
• Conversion caotings
• Polytetrafluroethane (PTFE)
• GRAPHITE: a naturally occurring solid lubricant with excellent lubricating
properties due
to its structure which consists of layers of carbon that can easily slide over each
other
reducing friction,
Used: in high temperature applications, lubricating of locks, air compressors, food
processing machine (applications where temperature is high or liquid lubricants may
causes contamination)
• Molybdenum Disulfide: a lamellar like solid lubricant similar to graphite, with a
very low
coefficient of friction
Used: as a carrier of oils
• Glasses: glass is a solid that becomes viscus to high temperatures thus serving
as a
liquid lubricant. Its poor thermal conductivity makes glass attractive because it
acts as a
thermal barrier between hot work pieces and relatively cool dies.
Uses: as a lubricant in, hot extrusion and hot forging
• PTFE: commonly known as Teflon is a synthetic solid lubricant with excellent non-
stick
and low friction properties. It’s desired for its chemical resistance and ability
to operate in
a wide range of temperatures.
Uses: in various applications like thread tape, coatings on bearings and seals.
• Conversion coatings:
Where lubricants do not adhere well to workpiece surfaces, particularly under high
normal
and shearing stress. Failure to adhere has detrimental effects, in processes such
as
forging, extrusion and wire drawing of STEELS, STAINLESS STEEL, and HIGH
TEMPERATURE ALLOYS.
For this reason the work piece surface is first transformed through a chemical
reaction
with acids hence the term conversion.
The surface then becomes rough and spongy, which acts as carriers for the
lubricant.
After treatment excess acid is removed using borax or lime.
A liquid lubricant eg soap can now be applied to the surface, it adheres and cannot
be
scraped off easily.
Examples of coating coumpounds:
1. Zink phosphate conversion coatings – carbon and low alloy steels
2. Oxate coatings – stainless steels and high temperature alloys
11. Outline the factors you will consider in the selection of metal working fluids.
• Specific manufacturing process
• Work piece material
• Tool or die material
• Processing parameters
• Comparability of fluid with the tool/die materials and workpiece
• Surface preparation required
• Method of applying the fluid
• Removal of the fluid and cleaning of the workpiece after processing
• Contamination of fluid by other lubricants, such as those used to lubricate
machinery
• Storage of waste lubricant
• Biological and environmental considerations
• Cost involved in all of the factors listed above

Question: What are the advantages of powder metallurgy technique over other types
of metal forming processes?
Answer:
• Minimal waste of material.
• Ability to form complex shapes.
• Good dimensional accuracy.
• Can combine dissimilar metals.
• Produces porous parts (e.g. self-lubricating bearings).

Question: Describe Atomization process of powder production for powder metallurgy

application. What advantages does it have over other types of powder production?
Answer:
Atomization: A molten metal stream is disintegrated by high-pressure jets of gas or
water into small droplets that solidify into powders.
Advantages: High production rate, uniform particle size distribution, suitable for
a wide range of metals.

Question: Describe the different chemical methods of powder production.

Answer:
• Reduction of oxides: Metal oxides reduced using gases (e.g. H₂, CO) to
form powders.
• Electrolytic deposition: Powders produced at cathode in electrolytic
cell.
• Chemical precipitation: Powders precipitated from solutions.

Question: What is sintering in PM process? Describe the various methods by which it

is achieved.
Answer:
Sintering: Heating compacted powders below melting temperature to bond particles
together.
Methods:
 • Solid-state sintering: Bonding by diffusion.
• Liquid-phase sintering: A small portion melts, aiding densification.
• Hot pressing: Pressure applied during sintering.
• Activated sintering: Additives accelerate diffusion.

Question: Discuss the industrial application(s) of Powder Metallurgy (PM).

Answer:
• Automotive parts (gears, bearings, bushings).
• Aerospace (turbine blades, filters).
• Electrical (contacts, magnetic materials).
• Medical (implants, surgical tools).
• Tools (carbide inserts, cutting tools).

Question: With illustration, describe the principles of:

• Electric discharge machining
• Ultrasonic machining
• Hydro-machining
Answer:
• EDM: Removes material using controlled sparks between tool and
workpiece in dielectric fluid.
• Ultrasonic machining: Tool vibrates at ultrasonic frequency with
abrasive slurry, removing hard and brittle materials.
• Hydro-machining: High-pressure water jet (with/without abrasives)
erodes material.