Q. What is an elastic strain? Why this is generally neglected in Mathematical theory of Plasticity?

Q. Derive true strain and conventional strain correlation and show that they are identical up to strain of 0.1?

Q. Calculate the factor of safety with following Strain-Stress data, using von mises yield criteria. All data are in
MPa?

x = 200, y = 100, z = -50, xy = 30, yz = xz = 0; Yield Strength of the Material is 500.

Q. What is Deformation efficiency, how it is calculated? Why extrusion efficiency is much less than rolling
efficiency?

Q. Why it is not possible to get large deformation in cold working compare to hot working. Calculate the
temperature increase during frictionless deformation process and with friction.

Q. State the effect of hot working temperature on the quality of Product. How to find out the suitable upper and
lower limit of hot working temperature.

Q. What are the Principal effect of Strain rate at metal working and give a comparative statements for different
testing and Forming Operations.

Q. Define workability. Draw a working limit diagram and describe it.

Q. What is workability with reference to Fracture?

Q. Why a flash is being used in closed die forging and how it is designed. Explain with diagram.

Q. Why compression of short cylinder is better measure of flow stress compare to same under Tension.

Q. What are the Principal values for the force calculation in the extrusion?

Q. Define Extrusion ratio. Why there is must be dead zone of metal in extrusion?

Q. What is the limiting Drawing Ratio for deep Drawing?

Q. Define Drawability and Factors affecting it. What are the types of steel used for deep drawing of cylinders?

Q. Sketch a Deep Drawing Process, Producing cylinder without any seam.

Q. State the function of lubricants in metal working and explain each of them briefly.

Q. What are the Forging Defects and how they can be minimised?

Q. Assume that average forging pressure of 340MPa is required, what is the largest closed-die forging could be
made on a Forging press having 350MN Press?

Q. Calculate the number of grains in the top surface of head of a pin (2.5mm diameter), if the pin is made from
steel ASTM grain size 6.

Q. If grain-size count reveals 3.4grains/cm2 on a photomicrograph taken at magnification of 250X, What is the
ASTM grain size number?
Q. The Particle spacing () is expressed as = 1/N v -2r where

Nv = No. of Particles per unit Volume,

r = radius of the Second Phase Particles uniformly distributed in the unit Volume of matrix,

f = volume of fraction of second phase particle.

Show that,

a) r, f , can be correlated as
= 2r [ 1/(1.91f)1/3 -1 ]
b) Plot f vs on a log-log graph paper and Calculate for the following combination.
f = 0.001 0.01 0.1
-5
r = 10 10-4 10-2 mm

Q. In the hot extrusion of Aluminium at 3150C, 0 = 83 MPa.

a) for a 300mm-diameter billet, 1m long, what is breakthrough pressure required to extrude a 75mm-diameter
bar if = 0.10 .

b) What is required extrusion Pressure at the end of the stroke?

c) What capacity Press would be needed for this extrusion.