E- Swaging and Thread Rolling

Question 1

What is the process that uses multiple dies that close on the part along radial paths. can be done with large machines or HAND TOOLS?

Answer 1

SWAGING

Question 2

What is a metal ring or cap that strengthens the end of a cable and prevents it from splitting or wearing?

Answer 2

FERRULE

Question 3

What are the tools used as a pumping action for deforming ferrous metals called?

Answer 3

HYDRAULIC SWAGING TOOLS

Question 4

What is an oversized pair of pliers that uses a compound lever action to generate large forces between the jaws (dies)?

Answer 4

HAND SWAGING TOOL

Question 5

What tool is hollow, but suddenly transitions from a hexagonal hole to a square hole and is preferred to be manufacture by SWAGING??

Answer 5

SOCKET of a RATCHET SOCKET WRENCH SET

Question 6

How are holes created in SWAGING? It is a metal tool around which other metal is formed, mirrors the internal cavity of the part?

Answer 6

MANDRELS

Question 7

What must be done to metal parts before being put through SWAGING?

Answer 7

OPEN DIE FORGED to create a WROUGHT STRUCTURE

Question 8

What is the process that allows long lengths of material to be SWAGED? A ring of cam followers is rotated while being driven inwards and outward.

Answer 8

ROTARY SWAGING

Question 9

How are “cold hammer forged barrels” for long guns made?

Answer 9

ROTARY SWAGING

Question 10

How is a Philips head screwdriver made?

Answer 10

SWAGING, doesn’t need a MANDREL because it is solid, not hollow

Question 11

Name the process where discrete products can be created between rotating dies (rollers) with an evolving shape attached around their perimeter.

Answer 11

ROLL-FORGING

Question 12

What is an example of ROLL-FORGING used to make steel balls for use in bearings. Two conical rollers with helical grooves of semicircular cross-section are offset at an angle ?

Answer 12

SKEW ROLLING

Question 13

What is another word for angled?

Answer 13

SKEWED

Question 14

What is a process that produces very long lengths of stock material using dies in the form of ROLLERS?

Answer 14

ROLLING

Question 15

What crushes the CAST STRUCTURE and turns it into a WROUGHT STRUCTURE, to reduce thickness?

Answer 15

ROLLERS

Question 16

Name the process where molten metal is formed into SLABS which then enters into the ROLLER stages which is non-stop.

Answer 16

CONTINUOUS CASTING

Question 17

What material is rolled using smooth and featureless rollers?

Answer 17

SHEET/PLATE STOCK

Question 18

What is rolling done at temperatures above recrystallization to avoid microcracking called?

Answer 18

HOT ROLLING

Question 19

What is an ADVANTAGE of ROLLING?

Answer 19

it provides stock with forged-like strength, inexpensive, long pieces of stock

Question 20

What are facilities where ROLLING is performed called?. these buildings can be up to 1/4 miles long.

Answer 20

ROLLING MILLS

Question 21

What is the final result of rolling processing called?

Answer 21

HOT ROLLED PLATE or SHEET

Question 22

What is the difference between PLATE and SHEET material?

Answer 22

PLATE material must be stacked flat
SHEET material can be coiled

Question 23

What is the black/gray coloration that forms on the surface of metal at elevated temperatures?

Answer 23

MILL SCALE/ BLACK IRON OXIDE

Question 24

What are the additional processing steps that turn HOT ROLLED STEEL into COLD ROLLED STEEL?

Answer 24

ANNEALING & PICKLING, TEMPER ROLLING

Question 25

What is the process called where the mill scale is removed?

Answer 25

PICKLING

Question 26

Name the process that reduces the thickness by a few thousandths of an inch at room temperature?

Answer 26

TEMPER ROLLING

Question 27

Name a softening heat treatment of the hot rolled steel

Answer 27

ANNEALING

Question 28

Name a ROLLING DEFECT.

Answer 28

wavy edges zipper cracks in the center of the flat rolling edge cracks alligatoring

Question 29

Name the ROLLING DEFECT where the end of the rolled product resembles the open jaws of an alligator. It is caused by the upper and lower surfaces of the material getting attached to the rollers.

Answer 29

ALLIGATORING

Question 30

Name the process used to create large circular workpieces using rollers

Answer 30

RING ROLLING

Question 31

Name the process done with linear style dies or with more traditional rollers similar to those in ROLL-FORGING.

Answer 31

SPLINE ROLLING

Question 32

What are grooves used to concentrically attach shafts together for torque transmission, and require proper grain flow for strength?

Answer 32

SPLINES

Question 33

What process uses grooved rollers to create STRUCTURAL STOCK from cast “bloom”, but can include a variety of additional rollers of various sizes, shapes, and orientations to form the required cross-sections?

Answer 33

SHAPE or PROFILE ROLLING

Question 34

What is the process where ROLLERS with helical grooving or LINEAR DIES with angled grooves create the threads of a bolt to be strong?

Answer 34

THREAD ROLLING

Question 35

What process will always produce weak, smooth, sharp, precise threads, and will result in a major diameter EQUAL to the shank.?

Answer 35

CUTTING THREADS

Question 36

What process is very strong, more rounded, and result in a major diameter that is LARGER than the shank.

Answer 36

ROLLED THREADS

Question 37

What is the “best of both worlds” between ROLLED and CUT THREADS?

Answer 37

PRECISION BOLTS