This set of Casting, Forming and Welding Multiple Choice Questions & Answers (MCQs) focuses on “Swaging”.
1. Swaging is a metal forming process in which material is deformed by performing bending operation.
a) True
b) False
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Explanation: Swaging is a metal forming process of reducing or shaping the cross-section of metallic rods by means of repeated impacts or blows. This process basically consists of dies which are given the required external shape. These dies intermittently impact the material to produce the deformation.
2. Better surface finish and grain structure of material are the main advantages of using the swaging process.
a) True
b) False
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Explanation: In the swaging process, hammering action is produced which provides better surface finish, tensile strength and better grain structure to the material. In this process, the work-piece should be completely clean and dry, and without any kind of lubricant. This method is very simple and can be performed by any unskilled operator.
3. In the swaging process, tubes cannot be swaged without the application of mandrels.
a) True
b) False
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Explanation: In the swaging process, tubes can be swaged with or without the application of mandrels. In the case of swaging without mandrels, the surface finish obtained will not be proper and accurate when a blow is applied onto the material during the operation. When the length and thickness of the material increases simultaneously, then the need of mandrel becomes essential.
4. Rotary swaging is a forming process which is used for making tubes of high precision.
a) True
b) False
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Explanation: Rotary swaging is a forming process which is mainly used for making tubes with high precision. This process can also be used making rods or bars, and it basically belongs to the group of net-shape forming processes, of which one of the features is that the finished shape of the material is produced without or with only a small quantity of further final processing by finishing.
5. The forming dies of swaging machine are generally arranged in an eccentric manner.
a) True
b) False
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Explanation: In the swaging process, the forming dies of the swaging machine are generally arranged concentrically around the material rod. The swaging dies operate with high frequency radial motions and with small strokes. The stroke frequencies commonly range from 1500 to 10000 per minute which basically depends upon the size of machine or equipment.
6. In rotary swaging, a unitary or single die is used during the processing of metallic bar or rod.
a) True
b) False
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Explanation: In rotary swaging process, the radial motions of the dies are very important for most of the applications. In general, a die set mainly consists of four die segments which basically depends on the type of application or use, and also depends on the size of the machine tool. In special cases of swaging, the number of die sets can be used up to eight dies.
7. A relative rotational motion between dies and materials is provided to prevent the formation of burrs during the process of swaging.
a) True
b) False
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Explanation: In swaging process, the formation of longitudinal burrs at the gaps between the dies is generally prevented by providing relative rotational motion between the dies and the materials. The swaging dies rotate near the material or alternatively, the material rotates between the die segments.
8. Rotary swaging process is also called as incremental forming or oscillating forming process.
a) True
b) False
View Answer
Explanation: Rotary swaging is basically an incremental forming process which is also called as oscillating forming, because it takes place in many small processing steps. One of the benefits of the incremental forming process compared to the continuous processes is the homogenous forming of the material. High forming ratios can also be achieved by a rotary swaging process in a single processing step.
9. Frictional wearing of dies is the major problem in the process of rotary swaging.
a) True
b) False
View Answer
Explanation: In rotary swaging, the main benefit of the incremental forming process is the minimum friction, because the time of contact between the dies and material is very small. And the relative movement is very small during the contact, so wearing of dies does not take place easily during the process.
10. In rotary swaging, the lubrication is not required significantly during the process.
a) True
b) False
View Answer
Explanation: In rotary swaging, the processing of the material is done by minimum relative motion and therefore minimum friction is present between the dies and materials. So the lubrication is not required significantly, but it is enough to use oil in a closed cycle which basically acts as a coolant or can be used for cleaning purpose.
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