Code No: RR322002 Set No.

1
III B.Tech Supplimentary Examinations, Aug/Sep 2008
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) Discuss Frank - Read mechanism of generating of dislocations.

(b) How Taylor’s Classical theory forms basis for Work hardening. Discuss.[8+8]

3. (a) Differentiate between Notching, Lancing and Slitting.

(b) Derive an expression for diameter of a smallest hole that can be punched.[8+8]

4. (a) Why clearance is required between Die and Punch. List out factors influencing
’clearance’. How the progressive tool is used for making washers ? Explain
with a sketch.
(b) Differentiate between Open Frame and Closed Frame presses. Discuss in detail
with sketch. What are the advantages and limitations of open frame press over
closed frame press. [8+8]

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) Why is lubrication difficult in Wire Drawing? Explain any one lubricating
method that is generally employed in Wire Drawing.
(b) What are the various materials used for making wire drawing dies? Explain
the application of each of them. [8+8]

7. (a) Sketch and describe the various sequence of operations in forging of an auto-
mobile connecting rod.
(b) Discuss various forging defects mentioning reasons and remedies. Suggest
suitable methods of reducing them in forged components? [8+8]

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Code No: RR322002 Set No. 1
8. (a) Explain the effect of ’Back Tension’ on Rolling process. Discuss its application
with the help of ’Friction Hill’. How the ’forward’ and ’backward slips’ will be
explained and its role in Rolling?
(b) Calculate rolling load if steel sheet is hot rolled to 30% from thick slab using
800 mm dia roll. Slab is 40 mm wide. Assume coefficient of friction is 0.3.
Plain strain flow stress is 138N/mm2 at entrance and 270N/mm2 at exit. In
the above problem, what would be load if the sticking Friction occurs? [8+8]

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Code No: RR322002 Set No. 2
III B.Tech Supplimentary Examinations, Aug/Sep 2008
METAL FORMING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Derive an equation of yield shear stress for uniaxial tension. How it can be
helpful to discuss about ’Yield criteria’ of metals.
(b) Explain Levy - Mises’ stress - strain relations? [8+8]

2. (a) Describe ‘dislocation’ theory. How a Burger’s Vector is generally used in

dislocation. How is displacement expressed by it ?
(b) Derive an expression for ‘Critical Resolved shear stress’. [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) What are the factors that influence selection of a press.

(b) Classify different presses for sheet working of metals. Discuss their principle
and specific applications.
(c) What are the advantages of Mechanical press over Hydraulic Press. [4+7+5]

5. (a) How do you analyse an extrusion process through a conical die. Determine
total extrusion pressure.
(b) Derive an equation for power loss in extrusion. [8+8]

6. (a) Sketch and describe the construction and working of hydrostatic extrusion and
mention some of its applications and advantages.
(b) Discuss the effects of deformation speeds, lubricants and different die materials
in hot and cold working processes. [8+8]

7. (a) Differentiate between Drop forging and Press forging operations. What are
the advantages of press forging over Drop forging.
(b) Enumerate the differences between Hot Forging, Cold Forging and Warm forg-
ing.
(c) Where forge welding is adopted ? How it can be classified ? Is it possible to
forge Cast Iron specimen. Give your comments. [6+4+6]

8. (a) Discuss various methods of applying lubricant during rolling process ? What
are the characteristics of a lubricant used during rolling.

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Code No: RR322002 Set No. 2
(b) Discuss briefly about the type of defects generally found in Rolled products ?
Mention their probable causes and remedies. [8+8]

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Code No: RR322002 Set No. 3
III B.Tech Supplimentary Examinations, Aug/Sep 2008
METAL FORMING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Derive an equation of yield shear stress for uniaxial tension. How it can be
helpful to discuss about ’Yield criteria’ of metals.
(b) Explain Levy - Mises’ stress - strain relations? [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) Discuss in detail about the process parameters and estimation of loads in Deep
Drawing.
(b) Discuss the following briefly with sketches.
i. Trimming dies and Bending dies
ii. Punching, and Fine Blanking. [8+8]

4. (a) Sketch and explain the working of progressive die. Indicate various elements
on it.
(b) Sketch a single die used in sheet metal working. How do you select clearances
between punch and die. Explain in detail. [8+8]

5. (a) How do you analyse an extrusion process through a conical die. Determine
total extrusion pressure.
(b) Derive an equation for power loss in extrusion. [8+8]

6. (a) In a wire drawing operation, determine the drawing stress and total drawing
load using following data:
Initial wire diameter = 6 mm
Final wire diameter = 3.2 mm
Die angle = 180
Die land = 4mm
Coefficient of friction = 0.15
Yield stress = 26Kg/mm2 .
(b) Indicate the composition of Extrusion die materials. Describe the causes of
defects that occur in Wire Drawing. [8+8]

7. (a) Describe the process of Press Forging with a neat Sketch. Enumerate the
merits and demerits of Forging.

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Code No: RR322002 Set No. 3
(b) List out different forging operations. Discuss in detail. [8+8]

8. (a) List out the different structural shapes formed by Rolling with sketches. Sketch
a Cluster Mill and indicate elements in it.
(b) Describe the principles of Ring Rolling and its applications. Mention its rela-
tive merits and limitations. [8+8]

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Code No: RR322002 Set No. 4
III B.Tech Supplimentary Examinations, Aug/Sep 2008
METAL FORMING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Derive an expression for strain tensor generally used in three dimensional stress
system.
(b) Why True stress - strain curve is called Flow Curve? Give reasons. How do
you indicate Flow curve mathematically? [8+8]

2. (a) Discuss the concept of ‘Strain Aging’. Explain its effect in flow curve of a low
carbon steel with a sketch.
(b) Define the following:
i. Dislocation climb
ii. Cross slip
iii. Jogs in dislocation
iv. Perfect and partial dislocation [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) Sketch and explain the working of a Compound die. Indicate various elements
in it.
(b) Sketch and explain the constructional details of Hydraulic press and mention
its salient features. [8+8]

5. (a) Derive an equation to calculate Extrusion Load.

(b) Discuss the common methods of extrusion processes with sketches. [8+8]

6. (a) Differentiate between ‘Surface Cracking’ and Internal Cracking of the extruded
product. How they can be explained? Mention methods of eliminating them.
(b) Name the important process variables in the drawing of rod and wire. Discuss
briefly. [8+8]

7. (a) Distinguish between Open Die and Closed Die Forging. Illustrate with exam-
ples. Give suitable sketches. What is Multi-Impression Die ? How it plays a
role in Forging.
(b) Discuss various parameters to be considered in the design of forging dies and
explain their effects on quality and finish of the components. [8+8]

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Code No: RR322002 Set No. 4
8. (a) Explain the principles and theory of Rolling with governing equations. How
seamless tubes are manufactured ?
(b) Deduce the differences between Forward slip and Backward slip. How Front
tension differs from Back Tension. In what way it affects Rolling ? [8+8]

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