Module 2 Tutorial Questions
1. Discuss the advantages and limitations of bulk metal forming compared to
other manufacturing processes like machining and casting.
2. Explain how temperature influences bulk metal forming. Compare hot
working, cold working, and warm working in terms of advantages,
disadvantages, and applications.
3. Explain the working principle of closed-die forging with the help of a neat
diagram. How does it ensure better dimensional accuracy?
4. A cylindrical workpiece of diameter 100 mm and height 150 mm is being
compressed in open-die forging. If the flow stress of the material is 200 MPa,
estimate the forging force required when the height is reduced to 100 mm.
5. Define rolling process. Explain the classification of rolling mills and their
working principles.
6. A steel plate of initial thickness 20 mm is reduced to 15 mm using a rolling
mill. The plate width is 500 mm, and the roll diameter is 600 mm. If the
average flow stress of the material is 250 MPa, estimate the rolling force
required.
7. If the max. reduction in rolling of slab is from 25 to 20 mm, calculate the value
of coefficient of friction. Take the roll diameter as 500mm. Also find the length
of projection of arc of contact.
8. If the coefficient of friction in cold rolling is 0.08, determine the i) length of
projection of arc of contact ii) the velocity of the slab at the exit iii) specific
roll pressure. Neglect lateral spread. Use the following data. Width of the
slab=b=80mm, Roll radius=800mm thickness of the slab=to=400 mm,
velocity of the slab at the entry=Vo=200 mm/sec, Rolling load=P=14MN.
9. A strip of lead with initial dimensions 24 mm x 24 mm x 150 mm is forged
between two flat dies to a final size of 6 mm × 96 mm x 150 mm. If the
coefficient of friction between the job and the dies is 0.25, determine the
maximum forging force. The average yield stress of lead in tension is 7
N/mm2.
10. A cylindrical workpiece is subjected to a cold upset forging operation. The
starting piece is 75 mm in height and 50 mm in diameter. It is reduced in
operation to a height of 36 mm. The work material has a flow curve defined
by values K = 350 MPa. and n = 0.17. Assume a coefficient of friction = 0.1,
determine force as the process begins, at intermediate heights of 62 mm, 49
mm, and at a final height of 36 mm.
Module 2 Tutorial Questions
11. Define wire drawing. Explain the step-by-step process of wire drawing and its
industrial applications.
12. What are the differences between shearing, blanking, and punching? Provide
industrial applications for each process.
13. What is deep drawing? Explain its working principle with a neat diagram.
14. Explain sheet metal forming. How does it differ from bulk metal forming?
Provide examples of sheet metal forming processes.
15. Discuss the deep drawing process in sheet metal forming. How does it differ
from other forming methods?
16. Explain the bending process in sheet metal forming. What are its advantages
and limitations?
17. Explain the role of dielectric fluid in EDM. What are its functions and types?
18. Explain the role of abrasive particles in AWJM. How do abrasive type, size,
and concentration affect the machining process?
19. Explain the influence of pulse current, voltage, and pulse duration on the
performance of Wire EDM.
20. What is Electro-Chemical Machining (ECM)? Explain its working principle
with a neat diagram.
21. Explain in detail. Why does ECM prefer for machining hard and complex
materials?
22. What is Ultrasonic Machining (USM)? Explain its principle with a neat
diagram.
23. Explain the function of the transducer in USM. How is it used to generate
ultrasonic vibrations?
24. Explain the role of vacuum in EBM. Why is it necessary for efficient
machining?
25. Explain the principle of Electron Beam Machining (EBM). How does electron
energy affect material removal?
26. Explain the working principle of Ultrasonic Machining (USM) with neat
sketches. Explain which materials can be processed using USM?