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Question 1:By application of tensile force, the crosssectional area of bar P is first reduced by 30% and then by an additional 20%. Another bar Q of the same material is reduced in crosssectional area by 50% in a single step by applying tensile force.

After deformation, the true strain in bar P and bar Q will, respectively be

After deformation, the true strain in bar P and bar Q will, respectively be

[PI 2008]

Question 2:A solid cylindrical stainless steel work piece of 200 mm diameter and 150 mm height. This component is reduced by 50% in height with flat die in open die forging. Assuming the flow stress of the material as 1000 MPa and the coefficient of friction to be 0.2 , the estimated forging force at the end of the stroke is

[PI 2006]

Question 3:Assertion (A): Cold working of metals results in increase of strength and hardness.

Reason (R): Cold working reduce the total number of dislocations per unit volume of the material

Reason (R): Cold working reduce the total number of dislocations per unit volume of the material

[PI 2005]

Question 4:Cold working produces the following effects

1. Stresses are set up in the material

2. Grain structure get distorted

3. Strength and hardness of the metal are increased

4. Surface finish is reduced

1. Stresses are set up in the material

2. Grain structure get distorted

3. Strength and hardness of the metal are increased

4. Surface finish is reduced

[PI 2003]

Question 5:An annealed copper wire of 25 mm diameter is drawn into a wire of 5 mm diameter. The average yield stress in this operation if the curve of the material is given, σ = 315 ε^{0.54} MPa

[PI 1994]

Question 6:Which one of the following manufacturing processes requires the provision of 'gutters'?

[PI 1994]

Question 7:In a linearly hardening plastic material, the true stress beyond initial yielding

[ME 2018,Set-1]

Question 8:It is desired to make a product having T-shaped cross-section from a rectangular aluminium block. Which one of the following processes is expected to provide the highest strength of the product?

[ME 2017,Set-2]

Question 9:Engineering strain of a mild steel sample is recorded as 0.100%. The true strain is

[ME 2016,Set-3]

Question 10:The strain hardening exponent n of stainless steel SS 304 with distinct yield and UTS values undergoing plastic deformation is

[ME 2015,Set-3]

Question 11:The operation in which oil is permeated into the pores of a powder metallurgy product is known as

[ME 2011]

Question 12:The force requirement in a blanking operation of low carbon steel sheet is 5.0 kN. The thickness of the sheet is 't' and diameter of the blanked part is 'd'. For the same work material, if the diameter of the blanked part is increased to 1.5d and thickness is reduced to 0.4t, the new blanking force in kN is

[ME 2007]

Question 13:In open-die forging, a disc of diameter 200 mm and height 60 mm is compressed without any barreling effect. The final diameter of the disc is 400 mm. The true strain is

[ME 2007]

Question 14:A 2 mm thick metal sheet is to be bent at an angle of one radian with a bend radius of 100 mm. If the stretch factor is 0.5, the bend allowance is

[ME 2005]

Question 15:Ductility of material with work hardening

[ME 2002]

Question 16:A test specimen is stressed slightly beyond the yield point and then unloaded. Its yield strength

[ME 1995]

Question 17:The true sliding strain for a low carbon Steel bar which is doubled in length by forging is

[ME 1992]

Question 18:In a rolling process, the state of stress of the material undergoing deformation is

[PI 2013]

Question 19:In a single pass rolling process using 410 mm diameter steel rollers, a strip of width 140 mm and thickness 8 mm undergoes 10% reduction of thickness. The angle of bite in radians is

[PI 2012]

Question 20:The thickness of a plate is reduced from 30 mm to 10 mm by successive cold rolling passes using identical rolls of diameter 600 mm. Assume that there is no change in width. If the coefficient of friction between the rolls and the workpiece is 0.1, the minimum number of passes required is

[PI 2011]

Question 21:In a rolling process, the roll separating force can be decreased by

[PI 2010]

Question 22:Anisotropy in rolled components is caused by

[PI 2009]

Question 23:In a rolling process, thickness of a strip is reduced from 4 mm to 3 mm using 300 mm diameter rolls rotating at 100 rpm. The velocity of the strip (in m/sec) at the neutral point is

[PI 2008]

Question 24:The maximum possible percentage reduction in area per pass during wire drawing of an ideal plastic material without friction is of the order of

[PI 2007]

Question 25:A copper strip of 200 mm width and 300 mm thickness is to be rolled to a thickness of 295 mm. The roll of radius 300 mm rotates at 100 rpm. The average shear strength of the work material is 180 MPa. The roll strip contact length and the roll force are

[PI 2006]

Question 26:If the elongation factor during rolling of an ingot is 1.22. The minimum number of passes needed to produce a section 250 x 250 mm from an ingot of 750 × 750 mm are

[PI 1992]

Question 27:Thread rolling is restricted to

[PI 1992]

Question 28:The blank diameter used in thread rolling will be

[PI 1989]

Question 29:The cold forming process in which a hardened tool is pressed against a workpiece (when there is relative motion between the tool and the workpiece) to produce a roughened surface with a regular pattern is

[ME 2019,Set-2]

Question 30:With respect to metal working, match Group A with Group B:

**Group A**

P. Defect in extrusion

Q. Defect in rolling

R. Product of skew rolling

S. Product of rolling through cluster mill

P. Defect in extrusion

Q. Defect in rolling

R. Product of skew rolling

S. Product of rolling through cluster mill

**Group B**

I. alligatoring

II. scab

III.fish tail

IV. seamless tube

V. thin sheet with tight tolerance

VI. semi-finished balls of ball bearing

[ME 2014,Set-2]

Question 31:In a rolling process, the state of stress of the material undergoing deformation is

[ME 2013]

Question 32:In a single pass rolling process using 410 mm diameter steel rollers, a strip of width 140 mm and thickness 8 mm undergoes 10% reduction of thickness. The angle of bite in radians is

[ME 2012]

Question 33:A solid cylinder of diameter 100 mm and height 50 mm is forged between two frictionless flat dies to a height of 25 mm. The percentage change in diameter is

[ME 2012]

Question 34:The maximum possible draft in cold rolling of sheet increases with the

[ME 2011]

Question 35:The thickness of a metallic sheet is reduced from an initial value of 16 mm to a final value of 10 mm in one single pass rolling with a pair of cylindrical rollers each of diameter of 400 mm. The bite angle in degree will be

[ME 2007]

Question 36:A 4 mm thick sheet is rolled with 300 mm diameter rolls to reduce thickness without any change in its width. The friction coefficient at the work-roll interface is 0.1. The minimum possible thickness of the sheet that can be produced in a- single pass is

[ME 2006]

Question 37:In a rolling process, sheet of 25 mm thickness is rolled to 20 mm thickness. Roll is of diameter 600 mm and it rotates at 100 rpm. The roll strip contact length will be

[ME 2004]

Question 38:Hot rolling of mild steel is carried out

[ME 2002]

Question 39:A strip with cross-sectional area 150 mm × 4.5 mm is being rolled with 20% reduction of area using 450 mm diameter rollers. The angle subtended by the deformation zone at the roll centre is (in radians)

[ME 1998]

Question 40:A wire of 0.1 mm dia is drawn from a rod of 15 mm diameter dies giving reductions of 20%, 40% and 80% are available. For minimum error in the final size, the number of stages and reduction at each stage respectively would be

[ME 1996]

Question 41:The extrusion processes used for the production of toothpaste tubes is/are

1. tube extrusion

2. forward extrusion

3. impact extrusion

[PI 2004]

Question 42:A moving mandrel is used in

[PI 1994]

Question 43:Semi brittle materials can be extruded by

[PI 1990]

Question 44:Collapsible tubes are made by

[Pl 1989]

Question 45:The maximum reduction in cross-sectional area per pass (R) of a cold wire drawing process is R = 1 – e^{–(n + 1)}

where n represents the strain hardening coefficient. For the case of a perfectly plastic material, R is

where n represents the strain hardening coefficient. For the case of a perfectly plastic material, R is

[ME 2018,Set-1]

Question 46:In a two-stage wire drawing operation, the fractional reduction (ratio of change in crosssectional area to initial cross-sectional area) in the first stage is 0.4. The fractional reduction in the second stage is 0.3. The overall fractional reduction is

[ME 2015,Set-2]

Question 47:In a wire drawing operation, diameter of a Steel wire is reduced from 10 mm to 8 mm. The mean flow stress of the material is 400 MPa. The ideal force required for drawing (ignoring friction and redundant work) is

[ME 2006]

Question 48:A brass billet is to be extruded from its initial diameter of 100 mm to a final diameter of 50 mm. The working temperature of 700°C and the extrusion constant is 250 MPa. The force required for extrusion is

[ME 2003]

Question 49:The process of hot extrusion is used to produce

[ME 1994]

Question 50:For wire drawing operation, the work material should essentially be

[ME 1987]

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