This set of Manufacturing Processes Interview Questions and Answers focuses on “Roll Forming – 2”.
1. EP 2 grease, high-temperature grease and chain and open-gear grease are used in roll forming equipment.
Explanation: EP 2 grease is used lubricating gears. This gear can handle heavy, suddenly applied loads in bearing application. High-temperature grease is used in weld boxes and other equipment that is subjected to a temperature above 200°F. Chain and open-gear grease are used on chain couplings, chain-driven components and open gear drives.
2. Which of the following oils is used in roll forming equipment?
a) SAE 140
b) SAE 30
c) Linseed oil
d) SAE 5W-30
Explanation: ISO grade 460 (SAE 140) Gear oil is used in sealed gearboxes. Gear oil has extreme pressure additives that strengthen the non-detergent oils to withstand heavy loads found in gears and gear drive systems.
3. In how many types roll forming lubricants are categorised?
Explanation: The different types of roll forming lubricants are listed below:
1. Evaporator compounds or vanishing oils
2. Chemical solutions (synthetics)
3. Micro-emulsions (semi-synthetics)
4. Macro-emulsions (solubles)
5. Petroleum based lubricants.
4. Chemical solutions (synthetics) ideal for coated steel.
Explanation: Chemical solutions are one of the fastest growing roll forming lubricant family. They are economical, environmentally safe, easy to handle, and are ideal for use on coated, galvanised, cold roll steel, aluminium, and in some instances, stainless steel.
5. Which of the following is used for lubrication in heavy-duty roll forming?
a) Extreme pressure-type solutions
b) Soap-type solutions
c) Non-ionic type solutions
Explanation: The soap-type solutions are used for heavy-duty roll forming. Non-ionic type solutions are excellent for roll forming aluminium and coated components and extreme pressure-type are used for high strength alloys.
6. For which of the following materials evaporative lubricants are used?
a) Hot rolled steel
b) Stainless steel
c) Ferrous and non-ferrous materials
Explanation: Evaporative lubricants are used for roll forming of painted, coated, and vinyl surfaces as well as ferrous and non-ferrous materials. They are applied using the proper type of airless spray system.
7. Which of the following is ideal for lubrication in roll forming of hot rolled and cold rolled steel?
c) SAE 120
d) SAE 20W 40
Explanation: micro-emulsions provide some film strength from the combination of emulsifiers, water-soluble corrosion inhibitors, wetting agents, organic and inorganic salts, and sometimes extreme pressure agents.
8. Macro-emulsions are also called as soluble oils.
Explanation: Macro-emulsions contain an oil-based lubricant, such as a mineral or compounded oil in the form of suspended droplets, which have been dispersed with emulsifiers due to which they become milky white appearance. Therefore, they are sometimes misleadingly called soluble oils.
9. Why additives are mixed with lubricating oil?
a) To reduce the friction
b) To increase the heat transfer
c) To change the colour
d) To improve the lubricant properties
Explanation: Additives are mixed to adjust the lubricants and make the suitable for a specific application. Additives improve lubricant’s properties, protect metal surfaces as well as perform many other functions.
Examples of additives: Rust and corrosion additives, EP additives, etc.
10. Pick the odd one out.
a) Sulphur compounds
c) Phosphorous compounds
d) Chlorine compounds
Explanation: Nitrates are usually used as rust or corrosion inhibitors; whereas compounds of sulphur, chlorine and phosphor are extreme pressure additives.
Sanfoundry Global Education & Learning Series – Manufacturing Processes.
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