Madan Mohan Malviya University of Technology

Gorakhpur, Uttar Pradesh

Department of Mechanical Engineering
(Unit-1, Tutorial-2)
Subject- Manufacturing Science (BME-254) Semester: 4th
Session: 2023-24

Q1. Derive an expression for pressure on workpiece in sliding zone in case of

forging a strip.

Q2. A hole of 60 mm diameter is to be produced in steel plate 2.5 mm thick. The

ultimate shear strength of the plate material is 450N/mm 2. If the punching
force is to be reduced to half of the force using a punch without shear,
estimate the amount of shear on the punch. Take the percentage penetration
as 40%.

Q3. For producing washer the following data is given; d = 12.7 mm , D = 25.4
mm , t = 1.25 mm, τs = 800 MPa, and C = 0.04 mm. Find (a) size of punches
and dies (b) force required if compound die is used (c) force required if
progressive die is used ( for both cases) (d) Assume 60 % penetration and
shear of 1 mm, what will be the force required, if both punches act tagether in
progressive die.

Q4. The force requirement in a blanking operation of low steel sheet is 5kN. The
thickness of sheet is t and diameter of blanked part is d. for the same work
material, if the diameter of blanked part is increased to 1.5d and thickness is
reduced to 0.4 t, the new blanking force in kN is
Q3. A steel cup of height 30 mm and internal diameter 40 mm with a flange of
width 10 mm is to be deep drawn from a sheet 1 mm thick. Determine the

(a) The diameter of blank (b) Drawing force

(c) Draw ratio

Q4. A strip with cross-section of 150*6 mm2 is rolled with 20% reduction in
area using 400 mm dia steel rolls. Before and after rolling, the shear yield stress
of material is 0.35kN/mm2 and 0.4kN/mm2 respectively. Calculate (a) Final strip
thickness (b) Average shear yield stress (c) Angle subtended by deformation
zone at roll centre (d) The location of neutral point and thickness of neutral
plane. Assume µ = 0.1.

Q5. Assuming the speed of rolling to be 30m/min, determine (i) the roll
separating force, (ii) the power required in the rolling process described in the
question no. 4, and (iii) If the diameter of the bearing in the given Q4 and Q5 is
150 mm and coefficient of friction in bearing is 0.005. Estimate the required
mill power.

Q6. In a single pass rolling operation, a 20 mm thick plate with plate width 100
mm, is reduced to 18 mm. The roller radius is 250 mm and rotational speed is
10 rpm. The average flow stress for the plate material is 300MPa. The power
required for the rolling operation in kW is closest to.

Q7. The thickness of 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

Q8. In a rolling process, sheet of 25 mm thickness is rolled 20 mm thickness.

Roll of diameter 6000 mm and it rotates at 100 rpm. The roll strip contact length
will be
Q9. A strip with a cross – section 150 mm * 4.5 mm is being rolled with 20 %
reduction of area using 450 mm diameter roll. The angle subtended by the
deformation zone at the roll centre ( In radian)

Q10. The thickness of plate is reduced from 30 mm to 10 mm by successive

cold rolling process using identical roll of diameter 600 mm. Assume that there
is no change in width. If the coefficient of friction between the rolls and
workpiece is 0.1, the minimum number of passes required is

Q11. In rolling processes, the thickness of strip is reduced from 4 mm to 3 mm

using 300 mm diameters rolls rotating at 100 rpm. The velocity of strip in m/s at
the neutral point is

Q12. A strip of 120 mm width and 8 mm thickness is rolled between 300 mm

diameter rolls to get a strip of 120 mm width and 7.2 mm thickness. The speed
of strip at the exit is 30 m/min. There is no front and back tension. Assuming
uniform roll pressure of 200 MPa in the roll bite 100 % mechanical efficiency,
the minimum total power (in kW) required to drive the two rolls is

Q12. What do you mean by defects in metal forming? Naming the different
defect which found in the various meal forming processes and explain their
causes and also remedies in various metal forming processes.

Q12. In a forging operation, the initial and final diameter of blank is 200 mm
and 400 mm. Height is 60 mm. find true strain.

Q13. A strip of lead with initial dimensions 24 mm * 24 mm*150 mm is forged

between two flat dies to a final size of 6 mm*96mm*150mm. If the coefficient
of friction is 0.05, determine the maximum forging force. The average yield
stress of lead in tension is 7N/mm2.

Q14. 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 of 30 mm, using slab method of analysis. The yield strength of work
material is given as 120N/mm2 and the coefficient of friction is 0.05. Assume
that volume is constant after deformation. There is no sticking. Also find the
mean die pressure.

Q15. A cylindrical specimen made up of steel is 150 mm in diameter and 100

mm high. It is upsetted by open die forging to a height of 50 mm. Assume that
coefficient of friction is 0.2. Calculate the force required to forge the material. If

the flow curve equation is σ f =¿ ¿1030❑

0.17
.

Q16. A circular disc of 200 mm diameter is 100 mm thick is compressed

between two dies to a thickness of 50 mm. Determine the maximum die
pressure if coefficient of friction is 0.1 and yield strength in compression is 230
MPa.

Q17.A certain disc of lead of radius 150 mm and thickness 50 mm is reduced to

a thickness of 25 mm by open die forging. If the coefficient of friction between
the job and die is 0.25 mm, determine the maximum forging force. The average
shear yield stress of lead can be taken as 4N/mm2.

Q18. A circular disc of 200 mm diameter and 70 mm height is forged to 40 mm

height. If the flowcurve equation of the material is given by σ f =¿ ¿

MPa . If the coefficient of friction is 0.05, determine forging load,
0.41
200 ¿(0.01+ ε )

mean die pressure and maximum pressure.

Q19. A plane-strain compression (forging) of block is shown in the figure. The

strain in the z-direction is zero. The yield strength (S y) in uniaxialy
tension/compression of the material of the block is 300 MPa and it follows the
Tresca (maximum shear stress) criterion. Assume that the entire block has
started yielding. At a point where σx = 40 MPa (compressive) and τxy = 0, the
stress component σy is------.
Q20. A bolt head has to be made at the end of a rod of diameter d = 12 mm by
localised forging (upsetting) operation. The length of the unsupported portion of
the rod is 40 mm. To avoid buckling of the rod, a closed forging operation has
to be performed with a maximum diameter of -----------mm.

Q21. Derive an expression for work load in the extrusion process.

Q22. Estimate the maximum force required for extruding the a cylindrical
aluminium billet of 50 mm diameter and 75 mm length to a final diameter of 10
mm. The average tensile yield stress for aluminium is 170N/mm 2. What
percentage of total power input will be lost in friction at the start of the
operation?

Q23. A round billet made of brass is to be extruded (extrusion constant = 250

MPa) at 700 0C. The billet diameter is 100 mm and the diameter of extrusion is
50 mm. The extrusion force required

Q24. Using direct extrusion process, a round billet of 100 mm length and 50
mm diameter is extruded. Considering an ideal deformation process (no friction
and no redundant work) extrusion ratio 4 and average flow stress of material
300 MPa, the pressure (MPa) on the ram will be.
 Madan Mohan Malviya University of Technology
Gorakhpur, Uttar Pradesh
Department of Mechanical Engineering
(Unit-2, Tutorial-1)
Subject- Manufacturing Science (BME-254) Semester: 4th
Session: 2023-24

Q1. Explain HAZ and weld quality and also describe the following welding
defects with causes and theirs remedies.

(a) Undercut (b) Slag inclusion (c) Hot Tearing

Q2. Explain the working of TIG with neat diagram. Compare it to MIG welding
process also.

Q3. Comment on the following welding processes with suitable diagrams in the
descriptive way.

(a) Brazing process (b) Atomic hydrogen welding (c) Submerged arc welding
(d) Soldering (e) Adhesive welding (f) Spot welding (g) Seam welding

(h) Projection welding

Q4. What do you mean by welding defect and also explain their causes and
remedies?

Q5. Classify welding process. Explain electric arc welding and resistance
welding with suitable diagram.

Q6. Explain Electro-slag welding and Friction welding. Also write the
application and limitation of both welding processes.
Q7. Sate and explain the solidification mechanism and micro-structural products
in welding metal. Give schematic illustration of microstructure during
solidification of weld zone.

Q8. What do you mean by defect found in the metal forming operations?
Comment on the following defect found in the various metals forming operation
in the descriptive way.

(a) Forging defect (b) Rolling defect (c) Extrusion defect

(d) Deep drawing defect.