Q1. Classify the types of extrusion.

Ans:

There are several types of extrusion, including:

1. Direct extrusion: Also known as forward extrusion, this process involves pushing material through
a die to create a desired shape.

2. Indirect extrusion: Also known as backward extrusion, this process involves pushing a container or
punch through a material to create a desired shape.

3. Co-extrusion: This process involves extruding multiple layers of material at the same time to
create a multi-layer product.

4. Profile extrusion: This process involves extruding a specific shape, such as a pipe or a cable
coating.

5. Blow extrusion: This process involves blowing air into the material while it is being extruded to
create hollow products such as tubes and bottles.

6. Cold extrusion: This process involves extruding material at a temperature below its
recrystallization temperature.

Q2. What is impact extrusion?

Ans: Impact extrusion is a manufacturing process in which a punch impacts a piece of metal or other
material, causing it to flow and take on the shape of the punch. The punch is typically cylindrical or
conical in shape, and is driven into the material with a high-speed press. The material is typically a
metal such as aluminium or steel, but other materials such as plastics can also be used. The process
is commonly used to create hollow parts such as cans, tubes, and containers. The impact extrusion
process is more efficient, faster and less costly than other metal forming processes like stamping,
spinning, and drawing. Additionally, it is capable of producing stronger and more complex shapes
with less material waste.

Q3. Why are a number of passes required to roll a steel bar?

Ans: A number of passes are required to roll a steel bar because the initial thickness of the bar is
typically much greater than the desired final thickness. Rolling one pass would not reduce the
thickness of the bar enough to achieve the desired final thickness, so multiple passes are required to
gradually reduce the thickness of the bar to the desired final dimensions.

Another reason is that the steel bar is not homogeneous, and it's not of the same thickness along its
entire length, so multiple passes are required to make the bar more uniform in thickness.

Additionally, in the rolling process, the steel bar is subjected to a significant amount of stress and
strain. If the bar is rolled in one pass, it could cause the bar to become distorted or even fracture. By
spreading the reduction in thickness over multiple passes, the stress and strain on the bar is
distributed more evenly, reducing the risk of distortion or fracture.

The number of passes required will depend on the initial thickness of the bar, the desired final
thickness, and the type of steel being rolled. In general, more passes will be required for thicker bars
or for bars made of harder, stronger steels.

Q4. How are seamless tubes produced?

1.Hot Rolling: The process starts with a solid round billet of steel that is heated to a high
temperature. The billet is then placed between a pair of rolls, which rotate in opposite directions.
The rolls apply pressure to the billet, which causes it to change shape and become longer and
thinner. As the billet is rolled, it is gradually reduced in diameter and increased in length.

2.Piercing: After the billet has been hot rolled, it is passed through a piercer, which is a large hollow
tube with a pointed mandrel inside. The mandrel is forced through the center of the billet, creating a
hollow tube. The tube is then drawn through a series of dies to reduce its diameter and increase its
length.

3.Heat Treatment: After the tube is rolled to the desired size, it is heat treated to improve its
properties such as strength, ductility, and toughness. The heat treatment process may include
normalizing, annealing, or quenching and tempering.

4.Inspection: The tube is then inspected for defects and compliance with the desired specifications
before it is shipped to the customer.

Q5. What is skew rolling?

Ans: Skew rolling is a method of forming steel balls or other cylindrical shapes by passing a billet
through a set of rotating rolls that are arranged at an angle to the axis of the billet. The billet is
heated to a high temperature before it is placed between the rolls, which apply pressure to the billet
and cause it to change shape and become a cylinder. The rolls are arranged at an angle, or skew, to
the billet's axis, which allows for more precise control of the shape and size of the finished product.

Skew rolling is commonly used to produce steel balls for use in ball bearings, grinding media, and
other applications.

Q6. Explain the term Extrusion process.

Ans: The extrusion process is a manufacturing method that involves forcing a material, typically a
metal or a plastic, through a die to create a desired shape. The material is typically heated to a high
temperature and then pushed through the die using a ram or a screw. As the material exits the die, it
takes on the shape of the die opening. The process is used to create a wide variety of products,
including pipes, tubing, rods, sheets, and profiles.

The extrusion process can be used to create a wide variety of shapes and sizes, and it can be used to
produce products made from a wide variety of materials, including metals, plastics, and ceramics.

One of the advantages of extrusion is that it is a relatively fast and efficient process that can produce
products with precise dimensions and a high degree of accuracy. Additionally, extrusion can be used
to create complex shapes and geometries that would be difficult or impossible to produce using
other methods.

Q7. Define Impact extrusion.

Ans: Impact extrusion is a metal forming process in which a punch (or die) is impacted onto a piece
of metal or other material, causing it to flow and take on the shape of the punch. The punch, which
is typically cylindrical or conical in shape, is driven into the material with a high-speed press. The
material is typically a metal such as aluminium or steel, but other materials such as plastics can also
be used.
The advantages of impact extrusion over other metal forming methods include:

 Greater precision and control over the shape and size of the final product.
 Greater strength and durability of the final product.
 The ability to create products with complex shapes and geometries that would be difficult or
impossible to produce using other methods.
 Greater efficiency and cost-effectiveness in production.
 Lower tooling cost.
 The ability to produce parts with a high degree of accuracy and consistency.

Q8. What is wire drawing?

Ans: Wire drawing is a manufacturing process in which a wire is pulled through a series of dies to
reduce its diameter and increase its length. The process can be done cold or hot, depending on the
type of material and the desired properties of the final product.

In cold wire drawing, the wire is pulled through a series of dies at room temperature. This process is
typically used for wires made of metals such as steel, copper, and aluminium. The process is
relatively fast and efficient, and it can produce wires with precise dimensions and a high degree of
accuracy.

In hot wire drawing, the wire is heated to a high temperature before it is pulled through the dies.
This process is typically used for wires made of metals that are difficult to work with at room
temperature, such as titanium and nickel alloys. The heat makes the wire more pliable and easier to
work with, and it can also be used to improve the properties of the final product.

Q9. What is deep drawing?

Ans: Deep drawing is a metal forming process in which a flat sheet metal blank is placed over a
punch and then drawn into a forming die using a press. The process is used to create a wide variety
of parts, including cups, cans, boxes, and other complex shapes.

Deep drawing is a cost-effective and efficient method of producing parts with complex shapes and
precise dimensions. Additionally, the process can be used to produce parts with a high degree of
uniformity and consistency.

Q10. Explain in brief wire drawing. How stock preparation is done in wire drawing?

Ans: Wire drawing is a manufacturing process in which a wire is pulled through a series of dies to
reduce its diameter and increase its length. The process can be done cold or hot, depending on the
type of material and the desired properties of the final product. In wire drawing, stock preparation is
the process of preparing the wire for drawing.

Stock preparation for wire drawing typically involves several steps:

1. Annealing: The wire is heated to a high temperature and then cooled in order to soften it
and make it more pliable. This is done to reduce the brittleness and improve the ductility of
the wire, making it easier to draw.
2. Cleaning: The wire is cleaned to remove any dirt, oil, or other contaminants that may be
present on the surface.
3. Descaling: Any scale or rust present on the wire is removed.
 4. Straightening: The wire is straightened to ensure that it is free from twists and kinks, which
could cause problems during the drawing process.
5. Cutting: The wire is cut to the desired length.
6. Coiling: The wire is coiled onto a reel for storage or for transportation to the wire drawing
machine.

Q11. What are different wire drawing dies used in Industries? Which material is preferable in wire
drawing dies and why?

Ans: Wire drawing dies are the tooling used to reduce the diameter of the wire during the wire
drawing process. There are several types of wire drawing dies used in industries, including:

1. Tungsten Carbide Dies: These dies are made of tungsten carbide, a hard and wear-resistant
material that can withstand high temperatures and pressures. Tungsten carbide dies are
typically used for drawing hard and brittle materials, such as stainless steel and high-carbon
steel.
2. Diamond Dies: These dies are made of synthetic diamond, which is the hardest known
material. Diamond dies are used for drawing materials that are extremely hard and difficult
to work with, such as tungsten and molybdenum.
3. PCD (Polycrystalline Diamond) Dies: These dies are made of diamond particles that are
sintered together under high pressure and temperature. They are used for drawing non-
ferrous metals, such as copper and aluminium, and soft materials such as gold and silver.
4. Ceramic Dies: These dies are made of ceramic materials such as aluminium oxide or silicon
nitride. Ceramic dies are used for drawing materials that are too soft for tungsten carbide
dies, such as gold and silver. They are also used for drawing materials that are sensitive to
heat, such as plastic.

The material that is preferable for wire drawing dies depends on the type of wire and the desired
properties of the final product. Tungsten carbide dies are the most commonly used because they are
hard, wear-resistant, and can withstand high temperatures and pressures. Diamond dies are used
for drawing extremely hard materials, while ceramic dies are used for drawing materials that are
sensitive to heat.

Q12. Explain Analysis of wire drawing operation

Ans: The analysis of wire drawing operation in the manufacturing process involves evaluating various
factors that affect the quality and efficiency of the wire drawing process, including the properties of
the wire, the design of the dies, and the operating conditions of the wire drawing machine.

1. Wire properties: The properties of the wire, such as its composition, microstructure, and
surface finish, can have a significant impact on the quality and efficiency of the wire drawing
process. Factors such as the wire's ductility, hardness, and tensile strength must be
considered to ensure that the wire can withstand the high stresses and strains of the
drawing process.
2. Die design: The design of the dies is also an important factor in the wire drawing process.
The dies must be designed to match the desired final shape of the wire and to provide a
smooth surface finish. The dies must also be made of a material that is harder than the wire
to ensure that they do not wear out quickly.
3. Operating conditions: The operating conditions of the wire drawing machine, such as the
speed of the wire, the force applied to the wire, and the temperature of the wire, can also
affect the quality and efficiency of the wire drawing process. It is important to control these
 conditions to ensure that the wire is drawn at the optimal speed and temperature to
produce a high-quality product.
4. Surface Finish: The surface finish of the wire is another important aspect to consider in wire
drawing. A smooth surface finish can be achieved by using proper lubrication and by
controlling the speed and force applied to the wire.

Q13. How the forces are acted in drawing operation. Which parameters are responsible for force
generation? What impact is observed when material passes through maximum reduction in one
pass?

Ans. In a wire drawing operation, the forces acting on the wire include the pulling force, the
frictional force, and the resistance force.

1. Pulling force: The pulling force is generated by the wire drawing machine and is used to pull
the wire through the die. This force is typically generated by a motor or by manual effort.
2. Frictional force: The frictional force is generated between the wire and the die, and it acts to
resist the movement of the wire through the die.
3. Resistance force: The resistance force is generated by the material of the wire, and it acts to
resist the deformation of the wire as it is drawn through the die.

The parameters that are responsible for force generation in wire drawing include:

1. Wire material: The material of the wire can affect the resistance force generated by the
wire. Harder materials will typically generate a greater resistance force than softer materials.
2. Die design: The design of the die can affect the frictional force generated between the wire
and the die. A well-designed die will minimize the frictional force and reduce the overall
force required to draw the wire.
3. Lubrication: The use of lubrication can reduce the frictional force between the wire and the
die, which can reduce the overall force required to draw the wire.

When material passes through maximum reduction in one pass, it is subjected to high stress and
strain. This can cause the material to become distorted or even fracture. Additionally, the material
may not have the desired final dimension.

Q14. Explain the concept Multiple and Strip Drawing.

Ans: Multiple drawing is a wire drawing process in which the wire is drawn through a series of dies to
reduce its diameter and increase its length. In this process, the wire is drawn through several dies in
succession, with each pass through a die reducing the diameter of the wire by a small amount. This
process is typically done cold.

Strip drawing is a similar process to multiple drawing, but it is used to reduce the thickness of a
metal strip rather than a wire. In this process, the metal strip is pulled through a series of dies to
reduce its thickness and increase its length. The strip is drawn through several dies in succession,
with each pass through a die reducing the thickness of the strip by a small amount.

Multiple and strip drawing are commonly used to produce wire and strip with precise dimensions
and a high degree of accuracy. They are typically used in industries such as electrical,
telecommunications, aerospace, and construction.

Q15. Explain the methods of Tube Drawing. Write the different forces acting in tube drawing
operation. Also explain why lubrication in necessary in Tube drawing
Ans: Tube drawing is a process in which a tube is pulled through a die to reduce its diameter and
increase its length. There are several methods of tube drawing, including:

1. Rod-Drawing: This method uses a mandrel to support the inside of the tube as it is drawn
through the die. The mandrel is typically made of a material that is harder than the tube
material.
2. Plug-Drawing: This method uses a plug to support the inside of the tube as it is drawn
through the die. The plug is typically made of a material that is softer than the tube material.
3. Die-Drawing: This method uses a die to support the inside of the tube as it is drawn through
the die. The die is typically made of a material that is harder than the tube material.
4. Free-Drawing: This method does not use any support for the inside of the tube as it is drawn
through the die.

The forces acting in tube drawing operation are:

1. Pulling force: The pulling force is generated by the tube drawing machine and is used to pull
the tube through the die.
2. Frictional force: The frictional force is generated between the tube and the die, and it acts to
resist the movement of the tube through the die.
3. Resistance force: The resistance force is generated by the material of the tube, and it acts to
resist the deformation of the tube as it is drawn through the die.

Lubrication is necessary in tube drawing to reduce the frictional force between the tube and the die,
which can reduce the overall force required to draw the tube. Lubrication also helps to prevent the
tube from sticking to the die, which can cause the tube to become distorted or even fracture.
Additionally, lubrication can help to improve the surface finish of the tube.

Q16. What are the different types of extrusion dies used in industry? Explain with application

Ans: There are several types of extrusion dies used in industry, including:

1. Straight dies: These dies have a straight bore and are used to produce straight, cylindrical
parts, such as pipes and tubes.
2. Conical dies: These dies have a tapered bore and are used to produce conical parts, such as
cones and funnels.
3. Co-extrusion dies: These dies are used for co-extrusion process, which is used to produce
multi-layer products. The die has multiple bores of different shapes and sizes.
4. Profile dies: These dies have a complex shape and are used to produce parts with complex
geometries, such as window frames and door frames.
5. Sheet dies: These dies are used to produce flat sheets of material, such as plastic sheets for
packaging.
6. Blow dies: These dies are used in blow extrusion process and have a hollow punch that
forms the internal shape of the product.
7. Micro-extrusion dies: These dies have very small bores and are used to produce very small
cross-sectional areas of material, typically used in the medical and electronics industry.

All these dies have specific application in manufacturing process:

 Straight dies are used to produce straight and cylindrical parts such as pipes, tubing and
rods.
 Conical dies are used to produce tapered parts such as funnels, cones and nozzles.
  Co-extrusion dies are used for producing multi-layer products such as plastic films, sheets
and tubings
 Profile dies are

Q17.Explain the concept : Extrusion Ration; Circumscribing circle diameter and Shape factor

Ans: Extrusion Ratio: The extrusion ratio is used to measure the amount of deformation that occurs
during the extrusion process. A high extrusion ratio indicates a high degree of deformation, which
can be desirable for certain products, but can also cause problems such as cracking or distortion.

Circumscribing circle diameter: The circumscribing circle diameter is used to measure the size and
shape of the extruded product. It is an important parameter to check for the consistency of the
product in terms of size, as well as to check if the product meets the design requirements.

Shape factor: The shape factor compares the actual cross-sectional area of the product to the cross-
sectional area of a perfect circle with the same circumscribing circle diameter. This parameter is
used to evaluate the shape of the product and its consistency. A shape factor close to 1 indicates
that the cross-sectional shape of the product is similar to a circle, while a shape factor less than 1
indicates that the product has a more complex shape.

Q18. How metal flow is observed in extrusion?

Ans: In the manufacturing process, metal flow in extrusion can be observed in several ways:

1. Visual inspection: The metal flow can be observed visually by watching the material as it is
extruded through the die. This can provide information about the shape and consistency of
the extruded product, as well as any potential defects or inconsistencies in the material flow.
2. Extrusion force measurement: The force required to extrude the material through the die
can be measured using a load cell or other force-measuring device. This can provide
information about the resistance of the material to deformation and can indicate if the
material is flowing smoothly or if it is experiencing any resistance.
3. Strain measurement: The deformation of the material can be measured using strain gauges
or other deformation measurement techniques. This can provide information about the
amount of deformation that the material is experiencing during the extrusion process.
4. Temperature measurement: The temperature of the material can be measured using
thermocouples or other temperature measurement techniques. This can provide
information about the temperature of the material during the extrusion process, which can
affect the flow of the material.
5. Speed measurement: The speed of the material can be measured using encoders or other
speed measurement techniques. This can provide information about the speed of the
material during the extrusion process, which can affect the flow of the material.

Q19. Enlist defects in extrusion, identify the reason why defects occurs and suggest remedies on
this.

Ans:

1. Bubbles: Bubbles can occur in the extruded material due to improper venting or insufficient
mixing of the materials. Remedies include ensuring proper venting and thoroughly mixing
the materials before extrusion.
2. Sink marks: Sink marks can occur due to uneven cooling or improper tooling. Remedies
include using proper tooling and ensuring even cooling of the extruded material.
3. Warping: Warping can occur due to uneven distribution of material or uneven cooling.
Remedies include using proper tooling and ensuring even distribution and cooling of the
extruded material.
4. Burn marks: Burn marks can occur due to overheating of the extruder or the extruded
material. Remedies include ensuring proper temperature control and using high-quality
materials.
5. Die swell: Die swell occurs when the material expands after it leaves the die. This can be
caused by improper die design or the use of low-quality materials. Remedies include using
proper die design and high-quality materials.
6. Surface defects: Surface defects can occur due to improper tooling or the use of low-quality
materials. Remedies include using proper tooling and high-quality materials.
7. Flash: Flash is a thin layer of extruded material that is extruded outside the die. This can be
caused by improper die design or the use of low-quality materials. Remedies include using
proper die design and high-quality materials.
8. Stringing: Stringing occurs when molten material hangs from the die or the extruded
material. This can be caused by improper die design or the use of low-quality materials.
Remedies include using proper die design and high-quality materials.