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engineering
materials science engineering

Questions and Answers of Materials Science Engineering

What are some of the negative aspects of hot working?
Describe how hot working can be used to improve the grain structure of a metal.
Why are heated dies or tools often employed in hot-working processes?
What are some of the disadvantages of cold-forming processes?
How could cold working be used to reduce the cost of a moderate-to-high-strength product?
How can the tensile test properties of a metal be used to assess its suitability for cold forming?
Why is elastic springback an important consideration in cold-forming processes?
What are Luders bands or stretcher strains, and what causes them to form?
What engineering properties are likely to decline during the cold working of a metal?
How can the selective placement of the final intermediate anneal be used to establish desired final properties in a cold formed product?
What are some of the advantages of warm forming compared to cold forming? Compared to hot forming?
What features have contributed to the slow development of warm working?
What material feature is considered to be the driving force for isothermal forming?
Why is isothermal forming considerably more expensive than conventional hot forming?
What is the significance of tool and die geometry in designing a successful metalforming process?
Why is lubrication often a major concern in metalforming?
What are some of the possible roles of a lubricant in addition to reducing friction?
What are some of the secondary effects that may occur when the speed of a metalforming process is varied?
Copper rod is being reduced from a hot-rolled 3/8-in. diameter to a final diameter of 0.100 in. by wire drawing through a series of dies. The final wire should have a yield strength in excess of
a. List and discuss the various economic factors that should be considered when evaluating a possible switch from cold forming to warm forming. b. Repeat part (a) for a possible conversion from hot
An advertisement for automobile spark plugs cited the superiority of rolled threads over machined threads. Figure 17-5 shows such a comparison for hot forming. The spark plug threads, however, were
The propeller of a moderately large pleasure boat has been cast from a nickel-aluminum-bronze alloy that contains 82% Cu, 9% Al, 4% Ni, 4% Fe, and 1% Mn. It is approximately 13 inches in diameter
Briefly describe the evolution of forming equipment from ancient to modern.
Why is foil almost always rolled on a cluster mill?
Why is speed synchronization of the various rolls so vitally important in a continuous or multistand rolling mill?
Explain how hot-rolled products can have directional properties and residual stresses.
Discuss the problems in maintaining uniform thickness in a rolled product and some of the associated defects.
Why is a "crowned" roll always designed for a specific operation on a specific material?
What is thermomechanical processing, and what are some of its possible advantages?
Why are steam or air hammers more attractive than board hammers for hammer forging?
What is the difference between open-die and impression-die forging?
Why is open-die forging not a practical technique for large-scale production of identical products?
What are some of the possible means of classifying metal-deformation processes?
What additional controls must be exercised to perform flash-less forging satisfactorily?
What is a blocker impression in a forging sequence?
What attractive features are offered by counterblow forging equipment, or impactors?
Why are different tolerances usually applied to dimensions contained within a single die cavity and dimensions across the parting plane?
Why are heated dies generally employed in hot-press forging operations?
Describe some of the primary differences among hammers, mechanical presses, and hydraulic presses.
What are some of the attractive features of automatic hot forging? What is a major limitation?
Why is the division of forming processes into hot working and cold working a somewhat nebulous classification?
How does roll forging differ from a conventional rolling operation?
What is meant by the term swaging?
What are some possible objectives of near-net-shape forging?
What are some of the attractive features of the extrusion process?
What is the primary attraction of indirect extrusion?
What property of a lubricant is critical in extrusion that might not be required for processes such as forging?
Why can lubricants not be used in conjunction with a spider-mandrel extrusion die?
How can tall, thin cups be produced by hot drawing? (The wall height is greater than can be produced in a single drawing operation.)
What is meant by the term ironing in hot-drawing operations?
What are some features of metals at elevated temperature that make hot forming an attractive technique to alter shape?
What limits the length of seamless pipe that can be produced by hot-piercing operations?
What are some of the common terms applied to the various shapes of rolled products?
Why are hot-rolled products generally limited to standard shapes and sizes?
Why is it undesirable to minimize friction between the work-piece and tooling in a rolling operation?
Why is it important to control the finishing temperature of a hot-rolling operation?
Discuss the relative advantages and typical uses of two-high rolling mills with large-diameter rolls, three-high mills, and four-high mills.
Consider the extrusion of a cylindrical billet, and compute the following. a. Assume the starting billet to have a length of 0.3 m and a diameter of 15 cm. This is extruded into a cylindrical product
The force required to compress a cylindrical solid between flat parallel dies (See Figure 18-10) has been estimated (by a theory of plasticity analysis) to bewhere R = radius of the cylinder T =
Mathematical analysis of the rolling of flat strip reveals that the roll-separation force (the squeezing force required to deform the strip) is directly proportional to the term 1 + K1mL /
If the area under the indirect extrusion curve of Figure 18-25 is proportional to the power required to extrude a product without billet-chamber frictional resistance, how could the relative regions
The components depicted in Figure CS-18 are two styles of mounting brackets used to attach outboard motors to the stern plates of small boats. The sketches show the parts as unfinished castings or
What are some of the attractive features of cold-working processes?
What is the unique capability provided by pressure-to-pressure hydrostatic extrusion?
What types of rivets can be used when there is access to only one side of a joint?
Why might hubbing be an attractive way to produce a number of identical die cavities?
How might a peening operation increase the fracture resistance of a product?
When making bends in sheet metal, what is the distinction between bending, forming, and drawing?
Why does a metal usually become thinner in the region of a bend?
What is springback, and why is it a concern during bending?
Why might cold-working equipment have to be more powerful than that used for hot working?
What factors determine the minimum bend radius for a material?
If a right-angle bend is to be made in a cold-rolled sheet, should it be made with the bend lying along or perpendicular to the direction of previous rolling?
From a manufacturing viewpoint, why is it desirable for all bends in a product (or component) to have the same radius?
What is the difference between air-bend and bottoming dies? Which is more flexible? Which produces more reproducible bends?
What type of products are produced by roll bending?
How can we prevent flattening or wrinkling when bending a tube?
What type of product geometry can be produced by cold-roll forming? Is the process appropriate for making short lengths of specialized products?
What are some methods for straightening or flattening rod or sheet?
What benefits can be obtained by subjecting sheet metal to a skin-rolling pass?
Why are sheared or blanked edges generally not smooth?
What measures can be employed to improve the quality of a sheared edge?
Why are fineblanking presses more complex than those used in conventional blanking?
Why might a long shearing cut be made in a progressive fashion?
What are the differences between piercing and blanking?
Why would you make the piercing punch shorter than the blanking punch in the progressive die set in Figure 19-50?
What is the purpose of having a shear angle on a punch?
Why would the cold rolling of shaped product not be an attractive means to produce a small amount of prototype product?
What is the major benefit of mounting punches and dies on independent die sets?
What is the major benefit of assembling a complex die set from standard subpress dies?
What is the benefit of making dies as a multipiece assembly?
What is a progressive die set?
What is the difference between progressive dies and transfer dies?
How do compound dies differ from progressive dies?
What is the attractive feature of a turret-type punch press?
What two distinctly different processes are often referred to as cold drawing?
What is the difference between tube drawing and tube sinking?
How can the swaging process impart different sizes and shapes to an interior cavity and the exterior of a product?
Why are rods generally drawn on draw benches, while wire is drawn on draw block machines?
Why are multiple passes usually required in wire-drawing operations?

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