ASSIGNMENT 1

1. What are the two main categories of metal forming processes? Give two examples of each (6 marks)
2. What is the function of the lubricant during forming? (2 marks)
2. Why can the blank not simply be lubricated with oil or grease during cold forming of aluminium? (2 marks)
3. How must the blanks be pre-treated (surface treated) before a cold forming pressing process? (4 marks)
4. What lubricants are used in cold forming? (3 marks)
5. What lubricants are used in drop forging?(2 marks)
7. Differentiate between cold forming and hot forming (3 marks)
8. Explain the merits of cold working over hot working(6 marks)
8. What is meant by deformability? (1 mark)
9. What factors does the deformability of aluminium material depend upon? (5 marks)
10. Explain these terms: (3 marks)
degree of upsetting
degree of lateral flow
degree of elongation.
ASSIGNMENT 2 (extrusion)
1. What extrusion methods do you know? (3 marks)
4. Name the most important elements of Aluminium extrusion tooling.
5. Why must the die be reinforced? (2 marks)
6. What values does the deformation efficiency depend upon? (3 marks)
7. What has gone wrong if internal surface cracks appear during backward extrusion? (2 marks)
9. What kind of work pieces are produced using backward extrusion and what with forward extrusion?
(4 marks)
10. What method must be used to produce a round-headed bolt?
11. What manufacturing process is used to produce a toothpaste tube? Sketch the sequence of
operations diagram.
12. Why is a pillar guide needed in extrusion tooling?
BENDING OF MATERIALS
1. What different types of bending process are there? (3 marks)
2. How is the length of the blank determined? (4 marks)
3. What bending machines do you know? (3 marks)
4. Name the three main bending processes. (3 marks)
5. What kinds of work pieces are produced using roll bending? (2 marks)
6. What machines is roll bending carried out on? (2 marks)
7. What are beading machines used for? (2 marks)
8. The Fig. below shows Aluminium roof rack of a passenger car. Describe the forming processes followed to
produce it


MACHINING OF ALLUMINIUM
1. Define the term machining (1 mark)
2. Briefly explain the factors that determines the machinability of Aluminium material (6 marks)
3. With help of diagrams explain the operating principles of the following Aluminium machining
equipment.
a. Milling machine (5 marks)
b. Turning machine (5 marks)
c. planning machine (5 marks)
4. What is automation?
5. Discuss the significance of automation in the manufacture and fabrication of Aluminium components
(6 marks)