Code No: RR322002 Set No.

1
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
METAL FORMING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. Explain the terms:

(a) “True Stress” and “True Strain”. How they differ from the concepts of Engg.
Stress and Engg. Strain
(b) Discuss the relationships between
i. True stress and Engineering stress
ii. True strain and Engineering strain [8+8]

2. (a) Differentiate between Point Defects and Surface Defects. Describe with dif-
ferent sketches.
(b) Differentiate between Ideal crystals and perfect crystals ? How the strength
of perfect crystals can be estimated ? [8+8]

3. (a) Describe the method of calculating cutting (shearing)/force in blanking and

punching.
(b) Explain the concept of Bending pressure. List out the Die-opening factors
for U-Bending and V-Bending. Why ‘Bottoming force’ is needed in Bending
operation. Explain where it is provided. [8+8]

4. (a) Sketch and explain the working of a transfer die used in practice. Explain
various elements used for it.
(b) Differentiate between Compound, Combination and Progressive dies. [8+8]

5. (a) Define ’Extrusion Ratio’. Differentiate between Hot extrusion and cold extru-
sion. Compare their relative merits and demerits.
(b) A drawn steel shell has an outside diameter of 70 mm and is made from 2.4
mm thick sheet having 2300kg/cm2 yield strength. If blank diameter is 136
mm. Calculate.
i. Dimensions of Punch and Die
ii. Drawing force. [8+8]

6. (a) What are the defects generally found in extruded components? Mention the
reasons and methods of elimination of these defects?
(b) Derive an equation for the force required in Wire Drawing process. [8+8]

7. (a) Sketch and describe the various sequence of operations in forging of an auto-
mobile connecting rod.

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Code No: RR322002 Set No. 1
(b) Discuss various forging defects mentioning reasons and remedies. Suggest
suitable methods of reducing them in forged components? [8+8]

8. Write short notes on the following:

(a) Types of Roll materials

(b) Process parameters in Rolling
(c) Defects in Rolling and their remedies
(d) Rolling Mills [16]

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Code No: RR322002 Set No. 2
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
METAL FORMING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Distinguish between engineering stress strain diagram and true stress strain
diagram. How they relate to each other.
(b) Details of a specimen subjected to tensile test are given below:
Initial diameter = 12 mm
Gauge Length = 50 mm
Maximum Load = 90 KN
Fracture Load = 70 KN
Diameter at Fracture = 10 mm
Calculate
i. True Fracture stress
ii. Engineering stress at maximum load
iii. True strain at Fracture
iv. Engineering strain at fracture [8+8]
2. (a) Differentiate between Hot working and Cold working operations. Mention
their advantages, limitations and applications.
(b) Discuss the various requirements of materials to be cold worked ? Name few
metals to be cold worked ? Explain how this process is suitable for close
dimensional tolerances. [8+8]
3. (a) Explain the process of bending operation? Discuss various types of bending
with neat sketches.
(b) How can spring back be offset? Explain the factors influencing spring back.
What is its application and relative merits. [8+8]
4. (a) How sheet-metal working operation differ from Drawing, Rolling, Forging and
extrusion?
(b) How the presses are useful for metal forming operations ? Explain their relative
advantages and applications. [8+8]
5. (a) What is drawing ? What type of components can be made by drawing oper-
ation ? Discuss the factors affecting drawing.
(b) A shell has an outside diameter of 60 mm and is made from mild steel of 3
mm thick. Calculate dimensions of punch and die. [8+8]
6. (a) Calculate the force required in extruding copper at 7000 C, if the billet diameter
is 125 mm and the extrusion ratio is 20. What is the purpose of dummy block
in extrusion?

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Code No: RR322002 Set No. 2
(b) Discuss the drawing of a cylindrical rod with a neat sketch. [8+8]

7. (a) Describe the process of Press Forging with a neat Sketch. Enumerate the
merits and demerits of Forging.
(b) List out different forging operations. Discuss in detail. [8+8]

8. (a) Why do we require different classification of rolling mills used in practice.

Mention their relative advantages and applications.
(b) How do you analyse the principles of roll pass design for different product
shapes. [8+8]

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Code No: RR322002 Set No. 3
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
METAL FORMING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. Explain the terms:

(a) “True Stress” and “True Strain”. How they differ from the concepts of Engg.
Stress and Engg. Strain
(b) Discuss the relationships between
i. True stress and Engineering stress
ii. True strain and Engineering strain [8+8]

2. (a) How a slip system can be indicated ? What is its significance ? Explain its
role in BCC, FCC and HCP Crystals. Discuss with neat sketch.
(b) Differentiate between Slip and Twinning. How a slip phenomena is helpful in
describing plastic deformation. [8+8]

3. (a) A steel washer of 28 mm outer diameter and 20 mm inside diameter is to

be made from 1.3 mm thick sheet. If the shear stress of the material is
380N/mm2 .
Calculate:
i. Force required to produce washer if both punches operate at the same
time with no shear. What will be stripping force?
ii. Force required if only one punch operates at a time (i.e. punches are
staggered)?
(b) Discuss the design principles of the following:
i. Punch length
ii. Punch plate
iii. Punch Holder. [8+8]

4. (a) A 300 KN Hydraulic press uses electrolytic copper sheets of 4 mm thick having
shear resistance 350N/mm2 in order to produce circular blanks of 50 mm
diameter. Calculate Blanking force required by press if
i. Shear provided on punch is 2 mm.
ii. No shear on punch
Assume percentage penetration is 30%.
(b) How the Guide posts are arranged in a die set ? Sketch and explain their
classification of different designs. [8+8]

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Code No: RR322002 Set No. 3
5. (a) Describe a basic extrusion process and indicate elements in it. Sketch some
typical cross-sections that are extruded.
(b) Discuss the effects of deformation speed, die materials and lubricants in hot
and cold working processes. [8+8]

6. (a) Classify different load estimation techniques in metal forming process. List out
assumptions in slab analysis, slip line field theory and upper bound solutions.
(b) Derive an equation for axial stress at die exit needed to cause deformation
during strip drawing of a wide sheet. [8+8]

7. (a) Define the concept of ’Forgeability’. Discuss various factors influencing it?
How the ’Hot Twist’ Test is performed to check forgeability.
(b) Describe the construction and working of a Board Drop Hammer. List out
some metals in the order of decreasing forgeability. [8+8]

8. (a) Differentiate between continuous rolling and controlled rolling. Give examples
of each. Mention the methods of reducing roll separating force.
(b) How the Rolling of I-Sections can be carried out using Mild Steel? Explain
with a neat sketch? [8+8]

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Code No: RR322002 Set No. 4
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
METAL FORMING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Discuss the concept of ’Super plasticity’ and the requirements to be fulfilled
to achieve superplasticity. Name few superplastic materials.
(b) Obtain the neat sketch of an Engineering stress-strain diagram for Aluminium
and indicate various salient points. [8+8]
2. (a) Discuss the effects of hot working and cold working on properties of metals?
(b) Explain the deformation of polycrystalline materials? [8+8]
3. (a) Define the term ‘Deep Drawability’. What is its usual range? How it can be
estimated? In what way it differs from Drawing?
(b) How do you estimate cutting forces in Blanking and Piercing? Derive the
governing equations. [8+8]
4. (a) Sketch and explain the working of a transfer die used in practice. Explain
various elements used for it.
(b) Differentiate between Compound, Combination and Progressive dies. [8+8]
5. (a) What are the defects found in extruded components ? Mention the reasons
and methods of eliminating them.
(b) A shell having 32 mm diameter and 108 mm height with a wall thickness of
0.8 mm is to be manufactured from 1.1 mm thick metallic sheet. Calculate
the blank diameter? [8+8]
6. (a) What are the defects generally found in extruded components? Mention the
reasons and methods of elimination of these defects?
(b) Derive an equation for the force required in Wire Drawing process. [8+8]
7. (a) Define ’Forging’. How it differs from Rolling, Drawing and extrusion. How
the closed-die forging can be performed ? Explain with a sketch.
(b) How are forging dies classified? Differentiate between Fillet and Corner radii?
What will happen if they are not provided in case of drop forging die? Explain
with sketch. [8+8]
8. (a) Estimate the ’Rolling Load’ in Rolling operation to reduce the thickness of a
plate. Explain with necessary equations?
(b) Sheet Metal Steel is reduced from 4.05 mm to 3.55 mm with 500 mm diameter
rolls having a coefficient of friction of 0.04. Mean flow stress in tension is
210N/mm2 . Neglect work hardening and roll flattening. Calculate

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Code No: RR322002 Set No. 4
i. Roll pressure at entrance to rolls
ii. Roll pressure at the neutral plane
iii. Roll pressure at the roll exit
iv. Roll pressure at neutral point if µ = 0.40. [8+8]

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