1. Forming is a process that changes the shape of the metal by changing its phase.

a) True
b) False
2. Which of the following components is mainly manufactured by performing metal forging?
a) Piston
b) Engine block
c) Connecting rod
d) Crankcase
3. The metal forging operation can only be performed by manual means.
a) True
b) False
4. Which of the following metal forming processes performs squeezing out of material through a
hole?
a) Forging
b) Rolling
c) Drawing
d) Extrusion
5. Metal forming is a process in which the metal is deformed plastically to get into the desired
shape.
a) True
b) False
6. Which of the following processes is not the type of bulk forming process in the metal forming?
a) Bending
b) Rolling
c) Forging
d) Extrusion
7. Which of the following manufacturing processes is mainly considered for producing the
components of very high strength?
a) Casting
b) Forging
c) Extrusion
d) Rolling
8. In metal forging process, the gravity drop hammers are operated by a ram using steam or
pressurized air.
a) True
b) False
9. Rolling is a forming process in which thickness of the metal plate is decreased by increasing its
length.
a) True
b) False
10. Which of the following metal forming processes is best suitable for making the wires?
a) Forging
b) Extrusion
c) Drawing
d) Rolling
11. Which of the following components are manufactured by the sheet metal forming process?
a) Engine blocks
b) Connecting rods
c) Electric wires
d) Car bodies
12. 2. Which of the following processes is not the type of metal forming process?
a) Extrusion
b) Injection moulding
c) Forging
d) Drawing
13. Cold forming is a process which works when the temperature of metal is above its re-
crystallization temperature.
a) True
b) False
14. Which of the following manufacturing processes operates under the influence of external
forces?
a) Metal forming
b) Powder metallurgy
c) Casting
d) Welding
15. Which of the following stresses is takes place during performing the wire drawing operation?
a) Tensile stress
b) Bending stress
c) Indirect compressive stress
d) Shear stress
16. Wire drawing process is almost similar to deep drawing process.
a) True
b) False
17. Closed die forging process is also called as impression die forging.
a) True
b) False
18. For the minimum metal loss, the flash-less forging is better than the impression die forging.
a) True
b) False
19. Formability is a mechanical property which defined as the ability of solid metal to get converted
into the liquid phase.
a) True
b) False
20. Shearing is a cutting operation in which material or work piece is subjected to shear stresses.
a) True
b) False
21. Which of the following can help in determining the behaviour of the material in metal forming?
a) Size of material
b) Shape of material
c) Stress-strain curve
d) Colour of material
22. A general stress-strain curve of any material represents the plasticity below the yield point.
a) True
b) False
23. Flow stress is defined as the instantaneous value of stress required to continue the deformation
of metal.
a) True
b) False
24. The mechanical strength of the metal decreases due to the strain hardening of the metal.
a) True
b) False
25. By keeping the metal at higher temperature, its ductility increases with the decrease in its
strength.
a) True
b) False
26. Better accuracy and surface finish is achieved by performing hot forming process instead of the
cold forming process.
a) True
b) False
27. In cold forming process, the fuel cost is very less as compared to that in the hot forming
process.
a) True
b) False
28. The extent of plastic deformation of material is mainly dependent on its grain structure.
a) True
b) False
29. In general, the coefficient of friction is very low in the metal forming processes.
a) True
b) False
30. In metal forming processes, the temperature rise also depends on the rate of deformation of the
material.
a) True
b) False
31. Which of the following is not a type of rolling mill?
a) Two-high rolling mill
b) Cluster rolling mill
c) Separation rolling mill
d) Tandem rolling mill
32. In two high rolling mills, what is the direction of rolling of the two rollers?
a) Clockwise-anticlockwise
b) Clockwise-clockwise
c) Anticlockwise-Anticlockwise
d) Stationery-clockwise
33. In two high rolling mills, if the direction of the rollers is reversed, what is it called?
a) Two high backward mill
b) Two high beneath mill
c) Two high reversing mill
d) Two high anti mill
34. In three high rolling mills, what is the direction of rolling of the three rollers?
a) Clockwise-clockwise- clockwise
b) Clockwise-anticlockwise- anticlockwise
c) Clockwise-anticlockwise- clockwise
d) Anticlockwise-anticlockwise-anti clockwise
35. How many rollers are used in four high rolling mills?
a) 3
b) 4
c) 8
d) 14
36. Which of the following property does not improve in the hot rolling process, of a cast?
a) Ductility
b) Shock resistance
c) Toughness
d) Boiling point
37. Which of the following articles cannot be made from rolling?
a) Rails
b) Helmets
c) Bars
d) Plates
38. Before beginning the process, the ingots are heated up to what temperature?
a) 1000°C
b) 1200°C
c) 1400°C
d) 1600°C
39. In hot rolling process, velocity of material at exit is lowest.
a) True
b) False
40. During rolling process, the thickness of workpiece squeezed is called what?
a) Shaft
b) Bore
c) Draft
d) Core
41. With an increase in starting thickness, how would it affect the reduction?
a) Increases
b) Decreases
c) Won’t change
d) Not related
42. How is the draft calculated?
a) Difference between starting and final thickness
b) Sum of starting and final thickness
c) Product of starting and final thickness
d) Ratio of starting and final thickness
43. Which of the following has the most magnitude?
a) Slip velocity
b) Surface velocity
c) Entering velocity
d) Exiting velocity
44. Which of the following has least magnitude?
a) Slip velocity
b) Surface velocity
c) Entering velocity
d) Exiting velocity
45. When a metal is entering, how are the width and the length of the workpiece related to each
other?
a) Direct relation
b) Inverse relation
c) Exponential relation
d) No relation
46. Roll velocity is lesser than exiting velocity.
a) True
b) False
47. When a material is being rolled, the perpendicular force on the arc is called what?
a) Thickness force
b) Roll force
c) Angle force
d) Die force
48. How would the draft be affected, if the radius of the roller is decreased?
a) Increase
b) Decrease
c) Won’t change
d) Not related
49. There is no slipping between roller and workpiece.
a) True
b) False
50. What is the general production rate in thread rolling?
a) 1000 pieces per minute
b) 2000 pieces per minute
c) 3000 pieces per minute
d) 4000 pieces per minute
51. When the material is entering the roller, what is the tension at the entry zone called?
a) Front tension
b) Above tension
c) Back tension
d) Beneath tension
52. How is the strength of the material, which is to be rolled, reduced?
a) Rolling at low temperatures
b) Rolling at high temperatures
c) Treating with ozone
d) Treating with carbon
53. In hot rolling, the temperature of working is uniform.
a) True
b) False
54. Which of the following process is done above the recrystallization temperature?
a) Hot forging
b) Cold forging
c) Impact forging
d) Gradual pressure forging
55. Which of the following method is used for manufacturing screws?
a) Hot forging
b) Cold forging
c) Impact forging
d) Gradual pressure forging
56. Which of the following method is used for manufacturing shafts?
a) Open die forging
b) Closed die forging
c) Impact forging
d) Flashless forging
57. The cost of cold dies is high.
a) True
b) False
58. In which of the following processes most noise is produced?
a) Press forging
b) Drop forging
c) Open die forging
d) Closed die forging
59. In which of the following processes most vibration is produced?
a) Press forging
b) Drop forging
c) Open die forging
d) Closed die forging
60. Drop forging is the most accurate form of forging.
a) True
b) False
61. Extrusion process is not suitable for which of the following?
a) Steel alloys
b) Non-ferrous alloys
c) Stainless steel
d) Iron
62. Which of the following is not made using extrusion?
a) Window frames
b) Doors
c) Helmets
d) Rods
63. What is the shape of the billet used in extrusion process?
a) Cubical
b) Spherical
c) Cylindrical
d) Pyramidal
64. Which of the following is also called as forward hot extrusion?
a) Direct extrusion
b) Indirect extrusion
c) Impact extrusion
d) Hydrostatic extrusion
65. Backward extrusion is another name for which of the following?
a) Direct extrusion
b) Indirect extrusion
c) Impact extrusion
d) Hydrostatic extrusion
66. In which of the following operations is a dummy block used?
a) Indirect extrusion
b) Direct extrusion
c) Impact extrusion
d) Hydrostatic extrusion
67. Indirect extrusion needs a large amount of force for functioning.
a) True
b) False
68. Up to what size can wires be drawn by wire drawing process?
a) 0.01mm
b) 0.02mm
c) 0.03mm
d) 0.04mm
69. Which of the following metal is used in the wire drawing process in die making?
a) Copper
b) Iron
c) Tungsten
d) Magnesium
70. A solid ram is used in direct extrusion.
a) True
b) False
71. Blanking is an operation in which the desired part is the sheet left out after making a punch hole
in it.
a) True
b) False
72. Die punch clearance is generally very critical for blanking as well as for punching operation.
a)True
b)False

73. . In blanking operation, the clearance is provided on the die for obtaining the blank from metal
sheet.
a)True
b)False

74. Fine blanking is a finishing operation in which shearing is done with very small clearances.
a) True
b) False
75. Which of the following parts is used for holding the metal sheet during blanking operation?
a)Spherical steel ball
b)Roller
c)Pressure pad
d)Magnet

76. Which of the following represents the approximate percentage of metal loss during the blanking
operation?
a)2%
b)5%
c)10%
d)30%

77. A power press machine is used in the blanking operation through which a punch is attached.
a)True
b)False

78. Forming dies are generally used in the blanking and piercing operations.
a)True
b)False

79. Progressive die is a die which can perform two or more operations in a single stroke.
a)True
b)False

80.
 81. Which of the following dies is not the type of cutting dies in the metal cutting operations?
a)Squeezing dies
b)Blanking dies
c)Piercing dies
d) Notching dies
82. Forging is a metal forming operation in which the metal is stretched to form the desired shape
of a metal part.
a) True
b) False
83. Precision forging is a type of forging operation in which the metal stocks and dies are controlled
very tightly.
a) True
b) False
84. In general, the casted metal part is much stronger and tougher than that produced by the
forging operation.
a) True
b) False
85. The open die forging process is also known as upsetting or upset forging process.
a) True
b) False
86. Which of the following processes is mainly used for making the connecting rods?
a) Casting
b) Deep drawing
c) Rolling
d) Forging
87. In open die forging process, homogenous deformation of billet has occurred with uniform
increase in its diameter.
a) True
b) False
88. In impression die forging process, extra deformed material is produced which is called a flash.
a) True
b) False
89. Isothermal forging is also known as cold forging operation.
a) True
b) False
90. The metal forging operation can be performed manually or by automation.
a) True
b) False
91. A cone shaped die is used in the orbital forging for the forging of metal parts.
a) True
b) False
92. Chances of crack propagation are more in

a. cold working process

b. hot working process
c. both a. and b.
d. none of the above

93. Which characteristic of material is used in forging process?

 a. characteristics of elasticity of material
b. characteristics of ductility of material
c. characteristics of plasticity of material
d. none of the above

94. Good surface finish and better dimensional accuracy can be achieved in

a. cold working process

b. hot working process
c. both a. and b.
d. none of the above

95. Hot working process is the plastic deformation of metal which is carried out

a. at temperature below the recrystallisation temperature

b. at temperature above the recrystallisation temperature
c. at temperature equals to boiling point of water
d. none of the above

96. Which of the following are the cold working processes?

(1) Forging
(2) Bending
(3) Squeezing
(4) Pipe Welding
(5) Drawing

a. (1), (2) and (3)

b. (2), (3) and (5)
c. (2), (4) and (5)
d. (1), (2), (3) and (5)

97. The volume of metal that enters the rolling stand

a. should increase after rolling process

b. should decrease after rolling process
c. should remain same after rolling process
d. unpredictable

98. How does the ability of material to withstand unpredictable loads change after
forging?

a. The ability of material to withstand unpredictable loads increases after forging

b. The ability of material to withstand unpredictable loads decreases after forging
c. The ability of material to withstand unpredictable loads does not change after forging
d. Unpredictable

99. Castings are usually

 a. costlier than forgings
b. cheaper than forgings
c. at the same rate as forging for similar metal
d. none of the above

100. What is the process, in which the metal is caused to flow through a restricted orifice to
create an extremely elongated strip of uniform and comparatively smaller cross-sectional
area, called?

a. Rolling
b. Extrusion
c. Drawing
d. Spinning