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1. Code: 12D87106b
M.Tech I Semester Supplementary Examinations September/October 2015
ADVANCED METAL FORMING
(Advanced Manufacturing Systems)
(For students admitted in 2011, 2012, 2013 & 2014 only)
Time: 3 hours Max. Marks: 60
Answer any FIVE questions
All questions carry equal marks
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1 (a) Classify the metal forming process. Write its advantages, disadvantages and applications.
(b) Differentiate Hot working and Cold working of metal with example and its effects on metal
properties.
2 (a) A copper strip, 9 in. (228 mm) wide and 1.00 in. (25 mm) thick, is rolled to a thickness of 0.80 in.
(20 mm) in one pass. The roll radius is 12 in. (300 mm) and the rolls rotate at 100 rpm. Calculate
the roll force and the power required in this operation.
(b) Discuss the prediction of roll pressure for flat strip rolling in the leading and lagging zone.
3 (a) Using open-die forging operation, a solid cylindrical piece of 304 stainless steel having 100 mm
dia x 72 mm height is reduced in the height to 60 mm at room temperature. Assuming the
coefficient of friction as 0.22 and the flow stress for this material at the required true strain as
1000 MPa, calculate the forging force at the end of stroke.
(b) What differences exist between drop forging and upset forging reference to the allowances to be
applied?
4 (a) Explain the advantages and disadvantages of compound dies over progressive dies.
(b) What is meant by clearance? Why is it important in shearing operation? Also explain the principle
of metal shearing.
5 (a) Explain how the various variables affect the extrusion pressure.
(b) Explain the production of seamless pipe processes with the neat sketches.
6 (a) In a wire drawing operation, initial wire diameter is 5.5 mm and the final wire diameter is 5 mm.
Die angle is 16 , die land is 3 mm and coefficient of friction is 0.1. Find the drawing load.
(b) Why is lubrication difficult in wire drawing? Explain any one lubricating method generally
employed in wire drawing.
7 Briefly explain the shearing, blanking, bending, stretch forming and deep drawing methods with a
neat sketch.
8 (a) With the help of a neat sketch explain HERF.
(b) Estimate the blanking force to cut a blank 25 mm wide and 30 mm long from a 1.5 mm thick
metal strip, if the ultimate shear stress of the material is 450 N/mm2
. Also determine the work
done if the percentage penetration is 25 percent of material thickness.
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