Assignment 6

 Explain the difference between extrusion amd drawing?
 Extrusion: It is a process where a billet is forced through a die.

Drawing: It is a process where a cross-section of solid rod, wire, or tubing is reduced
or changed in shape by pulling it through a die.
 What types of defects may occur in (a) extrusion and (b) drawing?
 (a) Surface Cracking, Pipe, and Internal Cracking.
 (b) Center Cracking and Seams.
 How are tubes extruded? can they also be drawn? explain.
 There are two ways of extruding tube: the porthole method and the seamless or
mandrel method.
Porthole extrusion is the most widely used process for making tube. A billet of
material is pushed over a former that creates the internal cross-section. This former
is held in place by ribs, so the material has to flow around them too. As it flows it
separates, so to make a tube the individual pieces are forced back together. Heat
and pressure work together to create a kind of weld or seam that’s practically
imperceptible to the human eye.
The alternative is to create an extrusion without seams along the length. This is done
by pushing a mandrel into the billet from the back. (The opposite end to the die.)
The tip of the mandrel goes almost all the way through the billet, stopping a short
distance from the extrusion die. This leaves a small gap between mandrel and die for
the metal to flow through.
After extrusion the hot tube is cooled and often subjected to stretching to improve
straightness. When a higher quality tube, a thinner wall or more consistent size are
needed extrusion is followed by a drawing process.
 What is the difference between cold, warm and hot forging ?

 The difference between cold, warm, and hot forging is the temperature for which
the forging is carried out at.
For example, cold forging is done at room temperature and warm and hot forging
are at elevated temperatures.
 Explain the difference between fullering, edging, and blocking.
 Fullering: Material is distributed away from an area.
Edging: Material is gathered into a localized area.
Blocking: The part is formed into the rough shape.
 What is flash? What is its function?

 Flash, also known as flashing, is excess material attached to a molded, forged, or cast
product, which must usually be removed. This is typically caused by leakage of the
material between the two surfaces of a mold or between the base material and the
mold in the case of overmolding.
Molding flash is seen when the optimized parameter on cull height is not calibrated.[citation
needed] Proper design of mold parting surfaces can reduce or eliminate flash.
 How can you tell whether a certain part is forged or cast? Describe the features that you
would investigate.
 Forged parts are often tougher than cast parts. This can be determined by
performing tensile tests on various areas on the parts. Additionally, the
microstructures of forged and cast parts can be used to determine if a part was
forged or cast. The microstructure of a cast part will have a more uniform grain
structure.
 What is the difference between a plate and a sheet?
 The distinction between sheet and plate is as equally ambiguous as a number of
other terms used to describe steel product forms. Generally speaking, a sheet is a
thinner item of metal that has been cut from a continuously rolled coil. As such, it
can be less than 1mm, or up to 25mm, in thickness. A plate is a thicker item of metal
that has been produced (rolled) as a single item. Thickness can be up to 150mm or
more, but also as low as 2mm from certain producers.
Therefore, it’s quite possible that certain thickness items could be produced via either
process and described differently, although both are in the hot rolled condition.
Plate metal is typically used in machines, structural sections and larger fabrications,whereas
sheet metal is used in producing appliances and enclosure
 Explain the difference between punching and blanking.

 In a punching operation, they typically remove the smallest amount of material
necessary from the original workpiece to minimize material waste. In contrast,
Blanking operations are most efficient when the maximum amount of material is
removed from the workpiece.
 What is the difference between deep drawing and redrawing?
 Deep drawing is a sheet metal forming process in which a sheet metal blank is
radially drawn into a forming die by the mechanical action of a punch.[1] It is
thus a shape transformation process with material retention. The process is
considered "deep" drawing when the depth of the drawn part exceeds its
diameter. This is achieved by redrawing the part through a series of dies. The
flange region (sheet metal in the die shoulder area) experiences a radial drawing
stress and a tangential compressive stress due to the material retention
property.
 What is the difference between a bloom,a slab, and a billet?
A bloom is a rolled steel workpiece with a square cross section of about 150 mm by
150 mm. ... A slab is rolled from an ingot or a bloom and has a rectangular cross
section of about 250 mm by 40 mm. A billet is rolled from a bloom and has a square
cross section of about 40 mm by 40 mm.

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Assignment 6

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 Explain the difference between extrusion amd drawing?

 Extrusion: It is a process where a billet is forced through a die.

 What is the difference between cold, warm and hot forging ?

Blocking: The part is formed into the rough shape.

 What is flash? What is its function?

 Explain the difference between punching and blanking.

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