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GATE‐2007
In open‐die forging, a disc of diameter 200 mm and

Forging height 60 mm is compressed without any barreling

effect. The final diameter of the disc is 400 mm. The
true strain is
(a) 1.986
1 986 (b) 1.686
1 686
(c) 1.386 (d) 0.602

Ans. (c)

By  S K Mondal

GATE‐1994 GATE‐1998
Match 4 correct pairs between List I and List II for List I List II
the questions List I gives a number of processes and (A) Aluminium brake shoe (1) Deep drawing
List II gives a number of products (B) Plastic water bottle (2) Blow moulding
List I List II (C) Stainless steel cups (3) Sand casting
(a)
( ) Investment
I t t casting
ti 1. Turbine
T bi rotorst (D) Soft drink can (aluminium)
(b) Die casting 2. Turbine blades (4) Centrifugal casting
(c) Centrifugal casting 3. Connecting rods (5) Impact extrusion
(d) Drop forging 4. Galvanized iron pipe (6) Upset forging
(e) Extrusion 5. Cast iron pipes Ans. (A) ‐3, (B) ‐2, (C) ‐1, (D) – 5
(f) Shell moulding 6. Carburettor body
Ans. (a) ‐ 2, (b) ‐ 6, (c) ‐ 5, (d) – 3

IES‐2008 IES – 2006

Which one of the following is correct? Assertion (A): Forging dies are provided with taper
Malleability is the property by which a metal or or draft angles on vertical surfaces.
alloy can be plastically deformed by applying Reason (R): It facilitates complete filling of die
(a) Tensile stress (b) Bending stress cavity and favourable grain flow.
(c) Shear stress (d) Compressive stress ( ) Both
(a) B th A and d R are individually
i di id ll true
t and
d R is
i the
th
Ans. (d) correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (c)

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IES – 2005 IES – 1996

Consider the following statements: Which one of the following is an advantage of
Forging reduces the grain size of the metal, which forging?
results in a decrease in strength and toughness. (a) Good surface finish
Forged components can be provided with thin (b) Low tooling cost
sections,
ti without
ith t reducing
d i the th strength.
t th (c) Close tolerance
Which of the statements given above is/are correct? (d) Improved physical property
(a) Only 1 (b) Only 2
(c) Both 1 and 2 (d) Neither 1 nor 2 Ans. (d)
Ans. (b)

IES – 1993 IES – 1997

Which one of the following manufacturing Assertion (A): In drop forging besides the provision
processes requires the provision of ‘gutters’? for flash, provision is also to be made in the forging
die for additional space called gutter.
(a) Closed die forging
Reason (R): The gutter helps to restrict the outward
(b) Centrifugal casting flow of metal thereby helping to fill thin ribs and
(c) Investment casting bases in the upper die.
(d) Impact extrusion (a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
Ans. (a) correct explanation of A
(c) A is true but R is false
(d) A is false but R is true [Ans. (c)]

IES – 2004 IES – 2003

Match List I (Different systems) with List II A forging method for reducing the diameter of a bar
(Associated terminology) and select the correct and in the process making it longer is termed as
answer using the codes given below the Lists:
(a) Fullering (b) Punching
List I List II
(c) Upsetting (d) Extruding
A. Riveted JJoints 1. Nipping
pp g
B. Welded joints 2. Angular movement
C. Leaf springs 3. Fullering Ans. (a)
D. Knuckle joints 4. Fusion
A B C D A B C D
(a) 3 2 1 4 (b) 1 2 3 4
(c) 1 4 3 2 (d) 3 4 1 2
Ans. (d)

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IES – 2002 IES – 1999

Consider the following steps involved in hammer Consider the following operations involved in
forging a connecting rod from bar stock: forging a hexagonal bolt from a round bar stock,
1. Blocking 2. Trimming whose diameter is equal to the bolt diameter:
3. Finishing 4. Fullering 5. Edging 1. Flattening 2. Upsetting
Which of the following is the correct sequence of 3. Swaging
S i 4. Cambering
C b i
operations? The correct sequence of these operations is
(a) 1, 4, 3, 2 and 5 (a) 1, 2, 3, 4 (b) 2, 3, 4, 1
(b) 4, 5, 1, 3 and 2 (c) 2, 1, 3, 4 (d) 3, 2, 1, 4
(c) 5, 4, 3, 2 and 1 Ans. (a)
(d) 5, 1, 4, 2 and 3 [Ans. (b)]

IES – 2003 IES – 2005

Consider the following steps in forging a connecting The process of removing the burrs or flash from a
rod from the bar stock: forged component in drop forging is called:
1. Blocking 2. Trimming (a) Swaging (b) Perforating
3. Finishing 4. Edging (c) Trimming (d) Fettling
Select the correct sequence of these operations using the
codes given below: Ans. (c)
Codes:
(a) 1‐2‐3‐4 (b) 2‐3‐4‐1
(c) 3‐4‐1‐2 (d) 4‐1‐3‐2
Ans. (d)

IES 2011 IES – 2008

Which of the following processes belong to forging The balls of the ball bearings are manufactured
operation ? from steel rods. The operations involved are:
1. Fullering 1. Ground
2. Swaging 2. Hot forged on hammers
3. Welding 3. Heat treated
(a) 1 and 2 only 4. Polished
(b) 2 and 3 only What is the correct sequence of the above
(c) 1 and 3 only operations from start?
(b) 1, 2 and 3 only [Ans. (a)] (a) 3‐2‐4‐1 (b) 3‐2‐1‐4
(c) 2‐3‐1‐4 (d) 2‐3‐4‐1
Ans. (None) Correct sequence is 2 – 1 – 3 ‐ 4

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IES – 2001
In the forging operation, fullering is done to   
(a) Draw out the material 
(b) Bend the material

Video (c) Upset the material

(d) Extruding the material

Ans. (a)

IES 2011 IES – 1998

Consider the following statements : The bending force required for V‐bending, U‐
1. Any metal will require some time to undergo complete bending and Edge‐bending will be in the ratio of
plastic deformation particularly if deforming metal has (a) 1 : 2 : 0.5 (b) 2: 1 : 0.5
to fill cavities and corners of small radii. (c) 1: 2 : 1 (d) 1: 1 : 1
2. For larger work piece of metals that can retain
toughness at forging temperature it is preferable to use Ans. (a)
forge press rather than forge hammer.
(a) 1 and 2 are correct and 2 is the reason for 1
(b) 1 and 2 are correct and 1 is the reason for 2
(c) 1 and 2 are correct but unrelated
(d) 1 only correct [Ans. (b)]

IES – 2005 IES – 2008

Match List I (Type of Forging) with List II (Operation) Match List‐I with List‐II and select the correct answer using the code
given below the lists:
and select the correct answer using the code given List‐I (Forging Technique) List‐II (Process)
below the Lists: A. Smith Forging 1. Material is only upset to get the desired shape
List I List II B. Drop Forging 2. Carried out manually open dies
C. Press Forging 3. Done in closed impression dies by hammers in
A. Drop Forging 1. Metal is gripped in the dies and blows
pressure is
i applied
li d on the
h heated
h d end
d D. Machine Forging 4. Done in closed impression dies by continuous
B. Press Forging 2. Squeezing action squeezing force
Code: A B C D
C. Upset Forging 3. Metal is placed between rollers and (a) 2 3 4 1
pushed (b) 4 3 2 1
D. Roll Forging 4. Repeated hammer blows [Ans. (c)] (c) 2 1 4 3
(d) 4 1 2 3
A B C D A B C D Ans. (a)
(a) 4 1 2 3 (b) 3 2 1 4
(c) 4 2 1 3 (d) 3 1 2 4

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IES – 1998 IES – 1994

Which one of the following processes is most In drop forging, forging is done by dropping
commonly used for the forging of bolt heads of (a) The work piece at high velocity
hexagonal shape? (b) The hammer at high velocity.
(a) Closed die drop forging (c) The die with hammer at high velocity
(b) Open
O die
di upsett forging
f i (d) a weight on hammer to produce the requisite
(c) Close die press forging impact.
(d) Open die progressive forging
Ans. (b) Ans. (c)

IES – 2009 IAS – 2001

Match List‐I with List‐II and select the correct answer using Match List I (Forging operations) with List II (Descriptions) and
the code given below the Lists: select the correct answer using the codes given below the Lists:
List‐I List‐II List I List II
(Article) (Processing Method) A. Flattening 1. Thickness is reduced continuously at
different sections along length
A. Disposable coffee cups 1. Rotomoulding B. Drawing 2. Metal is displaced away from centre,
B. Large g water tanks 2. Expandable
p bead moulding
g reducing thickness in middle and increasing
C. Plastic sheets 3. Thermoforming length
D. Cushion pads 4. Blow moulding C. Fullering 3. Rod is pulled through a die
5. Calendaring D. Wire drawing 4. Pressure a workpiece between two flat dies
Codes: A B C D A B C
Code: D
(a) A B C D (b) A B C D (a) 3 2 1 4 (b) 4 1 2 3
3 5 1 2 4 5 1 2 (c) 3 1 2 4 (d) 4 2 1 3
(c) A B C D (d) A B C D Ans. (b)
4 3 3 1 3 1 5 2
Ans. (d)

IAS – 2000 IAS – 1998

Drop forging is used to produce The forging defect due to hindrance to smooth flow
(a) Small components of metal in the component called 'Lap' occurs
(b) Large components because
(c) Identical Components in large numbers (a) The corner radius provided is too large
(d) Medium‐size components (b) The
Th corner radius
di provided
id d is
i too
t small ll
(c) Draft is not provided
Ans. (a) (d) The shrinkage allowance is inadequate
Ans. (b)

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IAS‐1996 IAS – 2002

Compound die performs Consider the following statements related to 
(a) Two or more operations at one station in one stroke forging:
(b) Two or more operations at different stations in one 1. Flash is excess material added to stock which flows 
stroke around parting line.
(c) Only one operations and that too at one work station 2. Flash helps in filling of thin ribs and bosses in upper 
Fl h h l  i  filli   f thi   ib   d b  i    
(d) Two operations at two different work stations in the die.
same stroke 3. Amount of flash depends upon forging force.
Which of the above statements are correct?
Ans. (a) (a) 1, 2 and 3 (b) 1 and 2
(c) 1 and 3 (d) 2 and 3 [Ans. (b)]

IES 2011 IES – 2006 ‐ Conventional

Assertion (A) : Hot tears occur during forging A certain disc of lead of radius 150 mm and thickness 50
because of inclusions in the blank material mm is reduced to a thickness of 25 mm by open die
Reason (R) : Bonding between the inclusions and forging. If the co‐efficient of friction between the job and
the parent material is through physical and die is 0.25, determine the maximum forging force. The
chemical bonding.
average shear yield stress of lead can be taken as 4
(a) Both A and R are individually true and R is the
N/mm2. [10 – Marks]
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (c)

IES – 2007 Conventional
A cylinder of height 60 mm and diameter 100 mm is
forged at room temperature between two flat dies. Find
the die load at the end of compression to a height 30
mm, using slab method of analysis. The yield strength of
the work material is given as 120 N/mm2 and the
coefficient of friction is 0.05. Assume that volume is
constant after deformation. There is no sticking. Also
find mean die pressure. [20‐Marks]