Final exam key answers

c) Name some products that are produced by extrusion.

Answer. Products produced by continuous extrusion include structural shapes (window frames,
shower stalls, channels), tubes and pipes, and rods of various cross sections. Products made by
discrete extrusion include toothpaste tubes, aluminum beverage cans, and battery cases.
d) Why is friction a factor in determining the ram force in direct extrusion but not a factor
in indirect extrusion?
Answer. Friction is a factor in direct extrusion because the work billet is squeezed against the walls
of the container so that friction resists the movement of the billet toward the die opening. In indirect
extrusion, the billet does not move relative to the container walls, and thus there is no friction.
Q.n Marks
o
1 a) 1. A) What is extrusion? 1.5
Answer. Extrusion is a compression forming operation in which a
workpiece is forced to flow through a die opening, thus taking the
cross-sectional shape of the die opening.

Answer. In direct extrusion, also known as forward extrusion, a metal billet is 2

loaded into a container, and a ram compresses the material, forcing it to flow
through a die opening at the opposite end of the container.
In indirect extrusion, also known as backward extrusion, the die is
incorporated into the ram, and as the ram compresses into the metal billet, the
metal is forced to flow through the die opening in a direction that is opposite
(backwards) of the ram motion.
Name some products that are produced by extrusion. 2.5
Answer. Products produced by continuous extrusion include structural shapes
(window frames, shower stalls, channels), tubes and pipes, and rods of various cross
sections. Products made by discrete extrusion include toothpaste tubes, aluminum
beverage cans, and battery cases.
1b Why is friction a factor in determining the ram force in direct extrusion 1.5
but not a factor in indirect extrusion?
Friction is a factor in direct extrusion because the work billet is squeezed against the
walls of the container so that friction resists the movement of the billet toward the die
opening. In indirect extrusion, the billet does not move relative to the container walls,
and thus there is no friction.
2 2+2+2.
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3 Blanking involves cutting of the sheet metal along a closed outline in a single step to separate the 3
piece from the surrounding stock, as in Figure 20.4(a). The part that is cut out is the desired product
in the operation and is called the blank.
Punching is similar to blanking except that it produces a hole, and the separated piece is scrap,
called the slug. The remaining stock is the desired part.

3b.
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5.
6.

6 a. Lap Joint.
 Butt Joint

6c, Show for the weld joints root of joint,groove and penetration.

The root of a joint is that portion of the joint where the metals are closest to each other. The
root may be a point, a line, or an area, when viewed in cross section
2. Groove is an opening or space provided between the edges of the metal parts to be
welded.

Root penetration refers to the depth that a weld extends into the root of the joint. Root
penetration is measured on the center line of the root cross section.
 Joint penetration refers to the minimum depth that a groove weld extends from its face
into a joint, exclusive of weld reinforcement.

Weld reinforcement is a term used to describe weld metal in excess of the metal
necessary to fill a joint.

6. d .

Weld defects, Cracks, Cavities, solid inclusions,Incomplete fusion,Imperfect shape or

unacceptable contour, miscelaneous defects