This set of Casting, Forming and Welding Multiple Choice Questions & Answers (MCQs) focuses on “Forging”.
1. Forging is a metal forming operation in which the metal is stretched to form the desired shape of a metal part.
a) True
b) False
View Answer
Explanation: Forging is a metal forming operation in which heated metal is beaten by a hammer to give it the desired shape. It is basically a deformation process in which the material is compressed between dies by using impact load to deform it. Forging can also be used for making complex shapes of metal parts.
2. Precision forging is a type of forging operation in which the metal stocks and dies are controlled very tightly.
a) True
b) False
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Explanation: In precision type forging operation, the volume of the metal stock and the dies are controlled very tightly. Such operations are called as precision forging which is a modern technique of forging. Metal parts of better strength, high quality details, and complex shape can be easily produced by the forging operation.
3. In general, the casted metal part is much stronger and tougher than that produced by the forging operation.
a) True
b) False
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Explanation: In general, forged parts are much stronger and tougher than the casted parts made from the same metal. The metal components have high strength because the hammering operation maintains its structure that makes proper alignment of grains along the profile of metal components, which leads to an increase in strength.
4. The open die forging process is also known as upsetting or upset forging process.
a) True
b) False
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Explanation: In an open die forging process, the metal billet is heated up to a very high temperature and then compressed between two flat die halves. This method is like a compression test, which is also known as upsetting or upset forging. In the process, billet is basically deformed by a decrease in its height and increase in its diameter.
5. Which of the following processes is mainly used for making the connecting rods?
a) Casting
b) Deep drawing
c) Rolling
d) Forging
View Answer
Explanation: Connecting rods are generally manufactured by the forging operation. In forging, a hammer is used which strikes on the heated metallic part to get into the desired shape. The properties like strength, toughness, etc are greatly enhanced by performing the forging operation. Forging can be open die forging or closed die forging.
6. In open die forging process, homogenous deformation of billet has occurred with uniform increase in its diameter.
a) True
b) False
View Answer
Explanation: In open die forging process, the deformation is not homogenous as bulging occurs due to the presence of friction at the interface of die and billet. This friction opposes the motion of billet; this effect is generally called as barreling effect. Homogenous deformation only occurs when the friction is zero, which is an ideal condition for the forging process.
7. In impression die forging process, extra deformed material is produced which is called a flash.
a) True
b) False
View Answer
Explanation: In impression die forging process, flash can be produced which is considered as scrap material that is removed from the formed part during the finishing of a metal part. But in flash-less forging, the metal is fully prevented within the die, so no flash is produced during the process.
8. Isothermal forging is also known as cold forging operation.
a) True
b) False
View Answer
Explanation: Isothermal forging is a hot forging operation in which the metal part is maintained at some high temperature. The forging dies are also maintained at the same high temperature. In this method, the metal flows readily that reduces the amount of force required. But this process is expensive than the conventional forging and mainly used for materials like titanium and super-alloys.
9. The metal forging operation can be performed manually or by automation.
a) True
b) False
View Answer
Explanation: Metal forging is a forming operation that performs hammering to shape the metal component. In forging process, the metal component is heated sufficiently, and then it is hammered by using a hammer which can be performed manually or by automation, depending on the scale of production and properties required in the forged metal component.
10. A cone shaped die is used in the orbital forging for the forging of metal parts.
a) True
b) False
View Answer
Explanation: In the orbital forging process, forming is done to the meat part by using a cone-shaped die that is simultaneously rolled and pressed into the material. The metal part is supported on a lower die, because of inclined axis of cone. In the process, only a small area of the metal surface is compressed at the stage of forming.
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