Materials Forming Processes: Shaping Techniques for Engineers

Question 1

In which forming process is molten material poured into a mold to solidify and take its shape?

Accepted Answer

Casting

Answer

Forging

Answer

Rolling

Answer

Extrusion

Question 2

In the forging process, what is the term used for the rhythmic blows applied to the metal to shape it?

Accepted Answer

Hammering

Answer

Pressing

Answer

Rolling

Answer

Extruding

Question 3

In extrusion, the primary forming parameter that determines the cross-sectional shape of the extruded product is the:

Accepted Answer

Die angle

Answer

Ram speed

Answer

Temperature

Answer

Billet material

Question 4

Which of the following material properties can be enhanced through work hardening during forming processes?

Accepted Answer

Strength

Answer

Ductility

Answer

Corrosion resistance

Answer

Thermal conductivity

Question 5

Which forming process is commonly used to produce long, thin sections of metal?

Accepted Answer

Extrusion

Answer

Casting

Answer

Forging

Answer

Rolling

Question 6

In cold rolling, what is the primary mechanism responsible for shape change during the process?

Accepted Answer

Plastic deformation

Answer

Elastic deformation

Answer

Phase transformation

Answer

Melting

Question 7

What is the primary purpose of annealing a material after a forming process?

Accepted Answer

To relieve internal stresses

Answer

To increase hardness

Answer

To improve corrosion resistance

Answer

To enhance electrical conductivity

Question 8

Which of the following is NOT a casting process?

Accepted Answer

Extrusion

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 9

What is the primary reason for forging a material?

Accepted Answer

To alter its shape and enhance its strength

Answer

To reduce porosity

Answer

To improve surface finish

Answer

To increase material toughness

Question 10

What is the main advantage of using extrusion over other forming processes?

Accepted Answer

Ability to produce shapes with complex geometries

Answer

High production rates

Answer

Improved material properties

Answer

Reduced material waste

Question 11

Which factor primarily influences the grain size in a forged component?

Accepted Answer

Temperature

Answer

Strain rate

Answer

Holding time

Answer

Die geometry

Question 12

What is the main limitation of the rolling process?

Accepted Answer

Limited shape complexity

Answer

High energy consumption

Answer

Poor surface finish

Answer

Slow production rates

Question 13

Which factor does NOT influence the extrusion pressure?

Accepted Answer

Ram speed

Answer

Material properties

Answer

Extrusion temperature

Answer

Die angle

Question 14

What is the primary purpose of using a mandrel in extrusion?

Accepted Answer

Producing hollow sections

Answer

Improving surface finish

Answer

Reducing material waste

Answer

Increasing production speed

Question 15

Which of the following is NOT a primary metal shaping process involved in materials forming?

Accepted Answer

Welding

Answer

Casting

Answer

Forging

Answer

Rolling

Question 16

Which type of rolling mill is NOT commonly used in the rolling process?

Accepted Answer

Planetary mill

Answer

Two-high mill

Answer

Three-high mill

Answer

Four-high mill

Question 17

Which of the following factors does NOT influence the formability of a material?

Accepted Answer

Density

Answer

Temperature

Answer

Strain rate

Answer

Grain size

Question 18

Which of the following is a commonly used non-destructive testing method?

Accepted Answer

Ultrasonic testing

Answer

Tensile testing

Answer

Hardness testing

Answer

Impact testing

Question 19

Which casting process involves pouring molten metal into a permanent mold made of metal or ceramic, producing parts with high dimensional accuracy and smooth surfaces?

Accepted Answer

Die casting

Answer

Sand casting

Answer

Investment casting

Answer

Centrifugal casting

Question 20

In forging, which of the following is NOT a type of deformation process used to shape metal?

Accepted Answer

Extrusion

Answer

Hot forging

Answer

Warm forging

Answer

Cold forging

Question 21

Which rolling process produces sheets with the highest dimensional accuracy and surface finish, making it suitable for applications requiring precise dimensions and aesthetics?

Accepted Answer

Cold rolling

Answer

Roughing rolling

Answer

Semi-finishing rolling

Answer

Hot rolling

Question 22

In hot forging, the recommended temperature range for most metals, which allows for optimal deformation and prevents defects, is:

Accepted Answer

Recrystallization temperature to melting temperature

Answer

Room temperature to recrystallization temperature

Answer

Above melting temperature

Question 23

What is the primary purpose of annealing in materials forming processes, such as hot rolling or forging?

Accepted Answer

To soften the material and relieve internal stresses

Answer

To harden the material

Answer

To increase the strength of the material