1. Forming is a process that changes the shape of the metal by changing its phase.

a) True

b) False

View Answer

2. Which of the following components is mainly manufactured by performing metal forging?

a) Piston

b) Engine block

c) Connecting rod

d) Crankcase

View Answer

3. The metal forging operation can only be performed by manual means.

a) True

b) False

View Answer

4. Which of the following metal forming processes performs squeezing out of material through a hole?

a) Forging

b) Rolling

c) Drawing

d) Extrusion

View Answer

5. Metal forming is a process in which the metal is deformed plastically to get into the desired shape.

a) True

b) False

View Answer

6. Which of the following processes is not the type of bulk forming process in the metal forming?

a) Bending

b) Rolling

c) Forging

d) Extrusion
View Answer

7. Which of the following manufacturing processes is mainly considered for producing the components
of very high strength?

a) Casting

b) Forging

c) Extrusion

d) Rolling

View Answer

8. In metal forging process, the gravity drop hammers are operated by a ram using steam or pressurized
air.

a) True

b) False

View Answer

9. Rolling is a forming process in which thickness of the metal plate is decreased by increasing its length.

a) True

b) False

View Answer

10. Which of the following metal forming processes is best suitable for making the wires?

a) Forging

b) Extrusion

c) Drawing

d) Rolling

1. Forming is a process that changes the shape of the metal by changing its phase.

a) True

b) False

View Answer

Answer: b

Explanation: Forming is basically a term that covers many manufacturing processes. In the metal
forming process, the shape of the material or metal is changed by performing an operation like
hammering, squeezing, bending, pulling etc. without changing its phase. The raw materials used in the
forming process remained in a single solid phase.

2. Which of the following components is mainly manufactured by performing metal forging?

a) Piston

b) Engine block

c) Connecting rod

d) Crankcase

View Answer

Answer: c

Explanation: Connecting rod is mainly manufactured by forging operation which is specifically known as
hot forging process, while parts like piston, crankcase and engine blocks are manufactured by a casting
process. In the forging process, a hammer is used which strikes on the heated metallic part to get into
the desired shape.

3. The metal forging operation can only be performed by manual means.

a) True

b) False

View Answer

Answer: b

Explanation: Metal forging is a forming operation which usually performs hammering process to shape
the metal part. In the forging process, the metal part is heated sufficiently, and then it is hammered by
using a hammer which can be performed by manual means or by automation, depending on the scale of
production.

4. Which of the following metal forming processes performs squeezing out of material through a hole?

a) Forging

b) Rolling

c) Drawing

d) Extrusion

View Answer

Answer: d

Explanation: Extrusion process is a type of metal forming process, in which the material is forced or
squeezed out through a hole called die. This process is very similar to squeezing out the toothpaste from
the tube. This process is mainly used for metals that are ductile in nature like copper, steel, aluminum
and magnesium; this process is also used for polymers.

5. Metal forming is a process in which the metal is deformed plastically to get into the desired shape.

a) True

b) False

View Answer

Answer: a

Explanation: In general, the metal forming is a large set of manufacturing processes in which the metal is
deformed plastically to get into the shape of the die geometry. The tools like dies and punches are
mostly used in the processes for the deformation of the material. For the plastic deformation, Stresses
beyond the yield strength of the material is required.

6. Which of the following processes is not the type of bulk forming process in the metal forming?

a) Bending

b) Rolling

c) Forging

d) Extrusion

View Answer

Answer: a

Explanation: Bulk forming is a deformation process which results in a massive shape change of the
material. The ratio of surface area to volume of the material is relatively small. It includes processes like
forging, extrusion and rolling. But the bending process is a part of sheet metal forming which has surface
area to volume ratio relatively high.

7. Which of the following manufacturing processes is mainly considered for producing the components
of very high strength?

a) Casting

b) Forging

c) Extrusion

d) Rolling

View Answer

Answer: b

Explanation: Forging is a deformation process in which the material is compressed between the dies by
using the impact load or hydraulic load. This process includes large forces which gradually or instantly
deformed the material resulting in production of variety of high strength components like connecting
rods, gears, jet engine turbine parts, aircraft parts etc.

8. In metal forging process, the gravity drop hammers are operated by a ram using steam or pressurized
air.

a) True

b) False

View Answer

Answer: b

Explanation: In the metal forming process, drop hammers are mainly of two types which are gravity
drop hammer and power drop hammer. Gravity drop hammers are the tools which achieve their energy
by the falling weight of a heavy ram. The force mainly depends on the height of the drop and the weight
of the ram. And power drop hammers are in which a ram is accelerated by the steam or pressurized air.

9. Rolling is a forming process in which thickness of the metal plate is decreased by increasing its length.

a) True

b) False

View Answer

Answer: a

Explanation: Rolling is a metal forming process in which the metal plate is squeezed between the two
hard rollers. In the operation, the thickness is decreases and the length is increased as the volume of the
metal is conserved. This method is mainly used for the production of thin metal plates which can be
done by performing hot rolling or cold rolling, depending on the required mechanical properties.

10. Which of the following metal forming processes is best suitable for making the wires?

a) Forging

b) Extrusion

c) Drawing

d) Rolling

View Answer

Answer: c

Explanation: Drawing is a metal forming process which is widely used for making the wires from round
bars of metal. This process is similar to extrusion process, except that instead of pressure on the metal
mass, in drawing, the wire is pulled from one side of the metallic round bar which results into the
formation of thin wires. This process is only suitable for ductile materials.
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

Answer: b

Explanation: Forging is a metal forming operation in which a 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

View Answer

Answer: a

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

View Answer

Answer: b

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 component, 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
View Answer

Answer: a

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 process, billet is basically deformed by 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

Answer: d

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 is occurred with uniform increase in its
diameter.

a) True

b) False

View Answer

Answer: b

Explanation: In open die forging process, the deformation is not homogenous as bulging occurs due to
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

Answer: a
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 any flash is produced during the process.

8. Isothermal forging is also known as cold forging operation.

a) True

b) False

View Answer

Answer: b

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 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

Answer: a

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

Answer: a

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.

1. Which of the following statement is true?

a) Casting is the replica of the object to be cast

b) Pattern is the replica of the casting object

c) Casting and the pattern are same things

d) Molten material is casted into the casting cavity

View Answer

Answer: b

Explanation: Pattern is the replica of the object. Except for the core prints and allowances, the pattern
exactly resembles the casting.

2. Which of the following carries the mould cavity where the metal is to be poured?

a) Casting

b) Pattern

c) Sand

d) Core

View Answer

Answer: b

Explanation: For casting to be made, the pattern is filled with the molten material and then it is allowed
to be solidified, using proper cooling rates before it is extracted out.

3. Which of the following is ‘not’ an allowance given to the pattern for casting?

a) Shrinkage

b) Draft

c) Hole

d) Machining

View Answer

Answer: c

Explanation: A hole is made during the machining or finishing of the casting and is not a type of
allowance given to the pattern.

4. The following diagram shows the application of which of the allowances given to a pattern?

a) Shrinkage allowance

b) Draft allowance

c) Shake allowance

d) Distortion allowance
View Answer

Answer: b

Explanation: Draft allowance is given so as to ease the removal of casting from the pattern without
damaging the pattern. Hence, tapering the vertical faces with some draft allowance is provided which is
machined later.

5. What will be the machining allowance for bore of a 405mm cast iron object to be casted?

a) 1.0mm

b) 2.0mm

c) 3.0mm

d) 5.0mm

View Answer

Answer: d

Explanation: The machining allowance for cast iron of various dimensions is shown in the table below.

DIMENSIONS(mm)

ALLOWANCE(mm)

BORE

SURFACE

COPE SIDE

upto 300

3.0

3.0

5.5

301-500

5.0

4.0
6.0

501-900

6.0

5.0

6.0

6. The quality of the final product is not dependent on _______________

a) Method of withdrawal of pattern

b) Allowance provided to the pattern

c) The complexity of the casting

d) The metal used in Casting

View Answer

Answer: d

Explanation: Metal used in casting is a concern till its viscosity affect the flow or occupation to the
cavity. This does not affect the final product physically, once the metal has solidified.

7. The life of a pattern is most likely to depend upon which of the following term?

a) Number of castings produced

b) Type of cooling rate of the casting

c) Size of the casting

d) Size of the pattern

View Answer

Answer: a

Explanation: Obviously, the more casting produced means more exposure of the pattern to the elevated
temperature of molten metals and hence, slowly causing distortion to the sand grains as well as the
pattern material.

8. What is the function of cores in the casting process?

a) To support the pattern

b) To provide differential cooling rates at specific portions

c) To make holes and cavities

d) For ease of flow of the molten material

View Answer
Answer: c

Explanation: Cores are the elements used to provide hollow cavities and holes in the pattern which are
difficult or non profitable to be given after the casting is done by machining.

9. Which of the following is ‘not’ an advantage of usage of pattern in a casting of metals?

a) Using patterns to cast objects, less time is consumed for mass production

b) It is cost efficient and profitable for mass production

c) Production of the pattern requires extra effort to cast the object

d) Cores in the pattern could be used to decrease the amount of machining done for making cavities

View Answer

Answer: c

Explanation: Production of patterns requires additional efforts but is justified for mass production only,
where more products are formed in less time and overcomes the effort and cost of making patterns.

10. A draft allowance is provided to ___________

a) All linear faces

b) Only the interior dimensions

c) Only the exterior dimensions

d) Only the dimensions that are perpendicular to the parting plane

View Answer

Answer: d

Explanation: The draft allowance is used for those dimensions which are perpendicular to the parting
plane, t1. Which of the following is not a part of the pattern at most times?
a) Mould cavity
b) Cope
c) Molten metal
d) Core
View Answer

Answer: c
Explanation: Molten material is poured into the mould cavity to make a casting, after solidification and
hence, it does not constitute the pattern.

2. Which of the following does not serve the purpose of using patterns in sand casting?
a) Contain core prints if the casting requires a core and need to be made hollow
b) To give the exact shape and size (in addition to the allowances) to the casting as that of the final
object
c) Reduces the cost of production while used in mass production
d) Sometimes used to carry the mechanism to melt the metal/material which is to be poured into the
cavity
View Answer

Answer: d
Explanation: The pattern never carries or includes the mechanism to melt the metal, which needs to be
poured into the cavity. This job needs to be done externally.

3. Name the missing part of the pattern in the diagram labelled as (?)?

a) Core
b) Riser
c) Sprue
d) Mould cavity
View Answer

Answer: a
Explanation: The illustrated part in the diagram is core. The core in a pattern is used to create holes or
hollow cavities.

4. The function of a gated pattern is ___________

a) To produce small castings in mass production
b) To create castings of a very heavy mass
c) To create castings containing complex design
d) To create symmetrical castings
View Answer

Answer: a
Explanation: Gated pattern manufactures huge no. of products using single time casting using a common
gating inlet system. Hence, the casting needs to be small and simple and is only justified for mass
production, as the pattern is used for 1-2 times only.

5. Which of the following factors affect the choice of a pattern at most times?
a) Size and complexity of the casting
b) Characteristics of castings
c) Type of molding and castings method to be used
d) Type of cooling rates to be provided
View Answer

Answer: d
Explanation: The type of cooling rates depends upon the required strength in the casting, which cannot
be controlled by the type of any pattern. Proper chills are to be used for that purpose.

6. Which of the following sequence is in the correct order to prepare a cast using the sand casting
method?
[1] Mould making [2] Clamping [3] Pouring [4] Cooling [5] Trimming [6] Removal
a) 1,3,2,4,6,5
b) 2,1,3,4,5,6
c) 1,2,3,4,5,6
d) 1,2,3,4,6,5
View Answer

Answer: d
Explanation: For a proper casting to be carried out, the correct order in which processes are to be
executed out starts with mould making then clamping it then pouring the metal then cooling then
removing it and at last trimming it or providing machining.

7. What is a function of a riser in a sand casting?

a) Provide good mobility to the molten metal
b) Prevent cavities due to shrinkage
c) To develop holes or hollow cavities in the casting
d) To provide differential cooling rates in specific areas of the casting
View Answer

Answer: b
Explanation: The risers also known as feeders are used to decrease the phenomena of shrinkage during
solidification of the molten metal.

advertisement

8. Runners, gates and risers are attached to the pattern to

a) Provide ease of cooling
b) Provide feed to the molten material
c) Provide design to the casting
d) Enhance the finishing of the casting
View Answer

Answer: b
Explanation: These external elements are added to the pattern or mould cavity to enhance the flow of
molten metal, hence, to enhance the casting process.

o give out a tapered face which is machined later