FORMING AND JOINING PROCESSES INTERVIEW QUESTIONS AND ANSWERS
What are the most common forming processes used in manufacturing?
Answer: The most common forming processes used in manufacturing are casting, forging, rolling, extrusion, and sheet metal forming.
What is casting?
Answer: Casting is a forming process in which molten metal or other material is poured into a mold and allowed to solidify into the desired shape.
What is forging?
Answer: Forging is a forming process in which metal is heated and then shaped by compressive forces, typically using a hammer or press.
What is rolling?
Answer: Rolling is a forming process in which a metal or other material is passed through a set of rollers to reduce its thickness or change its shape.
What is extrusion?
Answer: Extrusion is a forming process in which a material is forced through a die to create a continuous shape of the desired cross-section.
What are some common sheet metal forming processes?
Answer: Some common sheet metal forming processes include bending, deep drawing, stamping, and roll forming.
What is the difference between a closed die forging and an open die forging?
Answer: In a closed die forging, the metal is placed between two dies and then hammered or pressed into the desired shape, while in an open die forging, the metal is hammered or pressed into shape without being confined by a specific die.
What are some advantages of using casting as a forming process?
Answer: Some advantages of using casting include the ability to create complex shapes, the ability to use a wide range of materials, and the ability to produce large quantities of parts.
What is the difference between a hot forging and a cold forging?
Answer: In a hot forging, the metal is heated to a temperature above its recrystallization temperature before being shaped, while in a cold forging, the metal is shaped at room temperature or slightly above.
What is roll forming?
Answer: Roll forming is a sheet metal forming process in which a continuous strip of metal is passed through a series of rolls that gradually shape it into the desired profile.
What is a punch and die set in sheet metal forming?
Answer: A punch and die set is a tool used in sheet metal forming processes, such as stamping and punching, to create holes or shapes in the material. The punch is a tool that forces the material into the die, which is a tool that shapes the material into the desired form.
What is the difference between a deep drawing and a shallow drawing process?
Answer: In deep drawing, the depth of the drawn part is greater than its diameter, while in shallow drawing, the depth is less than the diameter.
What is a heat treatment process?
Answer: A heat treatment process is a manufacturing process in which a metal is heated and then cooled in a specific way to alter its properties, such as its hardness, strength, or ductility.
- What is the purpose of annealing in metalworking?
Answer: Annealing is a heat treatment process used in metalworking to improve the material's ductility, reduce its hardness, and remove internal stresses.
What is cold working in metal forming?
Answer: Cold working is a metal forming process in which the material is shaped or formed at room temperature or slightly above, without heating the metal.
What is the difference between a blank and a slug in metal forming?
Answer: In metal forming processes, a blank is a flat piece of material that is cut or punched from a larger sheet, while a slug is a piece of material that is punched out of a larger piece of material and discarded.
What is the purpose of a lubricant in metal forming?
Answer: Lubricants are used in metal forming processes to reduce friction between the tooling and the material being formed, which helps to prevent wear and tear on the tools and reduce the force required to form the material.
What is swaging in metal forming?
Answer: Swaging is a metal forming process in which a tube or bar is reduced in diameter by forcing it through a die or series of dies.
What is a die casting process?
Answer: Die casting is a manufacturing process in which molten metal is forced into a mold, or die, under high pressure to create a part with a specific shape and surface finish.
What is hydroforming?
Answer: Hydroforming is a metal forming process in which a fluid, typically water, is used to form the material into the desired shape. This process is often used to create complex, irregularly shaped parts.
What is a progressive die?
Answer: A progressive die is a type of tooling used in stamping and other metal forming processes to create parts with multiple features. The die contains multiple stages, each of which forms a different feature of the final part.
What is a draw die?
Answer: A draw die is a type of tooling used in metal forming processes to create parts with a curved or conical shape. The die is shaped to draw the material into the desired form.
What is a broaching process?
Answer: Broaching is a metalworking process in which a cutting tool, called a broach, is pushed or pulled through a part to create a specific shape or pattern.
What is the difference between a hot and cold rolling process?
Answer: In a hot rolling process, the material is heated before being passed through the rollers, while in a cold rolling process, the material is not heated and is processed at or near room temperature.
What is an end mill?
Answer: An end mill is a cutting tool used in milling machines to create a wide variety of shapes and features in metal and other materials.
What is a lathe?
Answer: A lathe is a machine tool used in metalworking to create cylindrical shapes by rotating
What is a welding process?
Answer: Welding is a metal joining process in which two or more pieces of metal are fused together by heating them to a high temperature and adding a filler material to create a strong bond.
What is brazing?
Answer: Brazing is a metal joining process similar to welding, but with lower temperatures. In brazing, a filler metal is melted and flowed into the joint between two metal pieces, creating a strong bond.
What is soldering?
Answer: Soldering is a metal joining process in which a filler metal, called solder, is melted and flowed into the joint between two metal pieces to create a strong bond.
What is a rivet?
Answer: A rivet is a metal fastener consisting of a cylindrical shaft with a head on one end and a tail on the other. The tail is deformed to create a permanent connection between two or more metal pieces.
What is a nut and bolt?
Answer: A nut and bolt is a type of fastener consisting of a threaded bolt and a matching nut. The bolt is inserted through a hole in one or more metal pieces, and the nut is tightened onto the end of the bolt to create a secure connection.
What is a threaded insert?
Answer: A threaded insert is a metal component that is inserted into a hole in a metal piece to provide a threaded surface for a bolt or screw to be inserted.
What is a tap and die set?
Answer: A tap and die set is a tool used to create threaded holes and screws in metal pieces. The tap is used to create a threaded hole, while the die is used to create a threaded screw.
What is a plasma cutter?
Answer: A plasma cutter is a machine tool used to cut metal and other materials using a high-temperature plasma arc.
What is a waterjet cutter?
Answer: A waterjet cutter is a machine tool used to cut metal and other materials using a high-pressure stream of water and abrasive particles.
What is a laser cutter?
Answer: A laser cutter is a machine tool used to cut metal and other materials using a high-energy laser beam.
What is a milling machine?
Answer: A milling machine is a machine tool used to create complex shapes and features in metal and other materials by removing material using a rotating cutting tool.
What is a lathe machine?
Answer: A lathe machine is a machine tool used to create cylindrical shapes by rotating a workpiece against a cutting tool.
What is a CNC machine?
Answer: A CNC (Computer Numerical Control) machine is a machine tool that is controlled by a computer to create precise shapes and features in metal and other materials.
What is EDM (Electrical Discharge Machining)?
Answer: EDM is a metalworking process in which a series of electrical sparks are used to erode material from a workpiece, creating a specific shape or feature.
What is a press brake?
Answer: A press brake is a machine tool used to bend sheet metal and other materials to create precise angles and shapes.
What is a shear machine?
Answer: A shear machine is a machine tool used to cut sheet metal and other materials to a specific size and shape.
What is a punch press?
Answer: A punch press is a machine tool used to punch holes and create other features in sheet metal and other materials.
What is a plasma arc welding process?
Answer: Plasma arc welding is a welding process in which a high-temperature plasma arc is used to melt and fuse metal pieces together.
What is a resistance welding process?
Answer: Resistance welding is a welding process in which two metal pieces are heated by passing an electrical current
What is friction welding?
Answer: Friction welding is a solid-state welding process that joins two metal pieces by heating them with frictional heat generated by rotating one piece against the other, then applying a compressive force to join them together.
What is ultrasonic welding?
Answer: Ultrasonic welding is a welding process in which high-frequency vibrations are used to generate frictional heat, melting the metal at the joint and creating a strong bond between two metal pieces.
What is explosive welding?
Answer: Explosive welding is a solid-state welding process in which two metal pieces are joined together by the force of an explosion, creating a strong bond between the two pieces.
What is roll bonding?
Answer: Roll bonding is a solid-state welding process in which two or more metal sheets are passed through a rolling mill to bond them together, creating a single sheet of metal with improved strength and ductility.
What is diffusion bonding?
Answer: Diffusion bonding is a solid-state welding process in which two metal pieces are held together at high temperature and pressure, causing the atoms at the interface to diffuse into each other and bond together.
What is cold welding?
Answer: Cold welding is a solid-state welding process that occurs when two clean metal surfaces are brought into contact under vacuum or inert gas, creating a bond without the need for heat or filler material.
What is hot gas welding?
Answer: Hot gas welding is a welding process in which a high-temperature gas flame is used to melt and join two plastic pieces together.
What is ultrasonic plastic welding?
Answer: Ultrasonic plastic welding is a welding process in which high-frequency vibrations are used to generate frictional heat, melting the plastic at the joint and creating a strong bond between two plastic pieces.
What is solvent bonding?
Answer: Solvent bonding is a welding process in which a solvent is used to dissolve the plastic at the joint, allowing the two plastic pieces to bond together.
What is adhesive bonding?
Answer: Adhesive bonding is a bonding process in which an adhesive is used to join two or more materials together, creating a strong and durable bond.
What is mechanical fastening?
Answer: Mechanical fastening is a process of joining two or more materials together using mechanical fasteners such as screws, bolts, nuts, rivets, or clips.
What is clinching?
Answer: Clinching is a process of joining two or more metal pieces together by deforming them to create an interlocking joint, without the need for any additional fasteners or adhesive.
What is crimping?
Answer: Crimping is a process of joining two or more metal pieces together by deforming them to create a mechanical interlock, using a specialized tool called a crimper.
What is interference fit?
Answer: Interference fit is a jointing technique where the inner diameter of one component is slightly smaller than the outer diameter of the other component, requiring an applied force to press them together and creating a tight and secure bond.
What is a flange joint?
Answer: A flange joint is a type of joint used to connect two pipes or other components, where a flange on each component is bolted together with a gasket to create a seal.
What is a clamp joint?
Answer: A clamp joint is a type of joint used to connect two components by clamping them together, using a bolt or other fastener.
What is a snap fit joint?
Answer: A snap fit joint is a type of joint used to connect two components by snapping them together, using a designed geometry or force.
What is a lap joint?
Answer: A lap joint is a type of joint used to connect two metal pieces by overlapping them and joining them together with welding or mechanical fasteners.
What is a scarf joint?
Answer: A scarf joint is a type of joint used in woodworking and construction to join two pieces of material end-to-end by tapering the ends of the two pieces and gluing or nailing them together.
What is a mortise and tenon joint?
Answer: A mortise and tenon joint is a type of joint used in woodworking to join two pieces of material at right angles, where a projecting part of one piece (the tenon) is inserted into a corresponding slot in the other piece (the mortise).
What is a dowel joint?
Answer: A dowel joint is a type of joint used in woodworking to join two pieces of material together by inserting a dowel (a cylindrical piece of wood or metal) into corresponding holes drilled in each piece.
What is a biscuit joint?
Answer: A biscuit joint is a type of joint used in woodworking to join two pieces of material together with a thin, oval-shaped piece of wood (the biscuit) inserted into matching slots in the two pieces.
What is a pocket hole joint?
Answer: A pocket hole joint is a type of joint used in woodworking to join two pieces of material together at an angle, where a special drill bit creates a pocket hole in one piece, and a screw is driven through the hole and into the other piece.
What is a tongue and groove joint?
Answer: A tongue and groove joint is a type of joint used in woodworking to join two pieces of material edge-to-edge, where a projecting tongue on one piece fits into a corresponding groove in the other piece.
What is a butt joint?
Answer: A butt joint is a type of joint used to connect two pieces of material together by joining them end-to-end, often with welding or adhesive.
What is a scarf joint?
Answer: A scarf joint is a type of joint used in woodworking and construction to join two pieces of material end-to-end by tapering the ends of the two pieces and gluing or nailing them together.
What is a mortise and tenon joint?
Answer: A mortise and tenon joint is a type of joint used in woodworking to join two pieces of material at right angles, where a projecting part of one piece (the tenon) is inserted into a corresponding slot in the other piece (the mortise).
What is a dowel joint?
Answer: A dowel joint is a type of joint used in woodworking to join two pieces of material together by inserting a dowel (a cylindrical piece of wood or metal) into corresponding holes drilled in each piece.
What is a biscuit joint?
Answer: A biscuit joint is a type of joint used in woodworking to join two pieces of material together with a thin, oval-shaped piece of wood (the biscuit) inserted into matching slots in the two pieces.
What is a pocket hole joint?
Answer: A pocket hole joint is a type of joint used in woodworking to join two pieces of material together at an angle, where a special drill bit creates a pocket hole in one piece, and a screw is driven through the hole and into the other piece.
What is a tongue and groove joint?
Answer: A tongue and groove joint is a type of joint used in woodworking to join two pieces of material edge-to-edge.
What is a half-lap joint?
Answer: A half-lap joint is a type of joint used in woodworking where each piece of wood is notched halfway through, and the notches are then glued or nailed together to create a strong connection.
What is a box joint?
Answer: A box joint is a type of joint used in woodworking to join two pieces of material together with interlocking fingers, creating a strong and durable connection.
What is a dovetail joint?
Answer: A dovetail joint is a type of joint used in woodworking to join two pieces of material together with interlocking angled fingers, creating a strong and durable connection that resists pulling apart.
What is a finger joint?
Answer: A finger joint is a type of joint used in woodworking to join two pieces of material together with interlocking rectangular fingers, creating a strong and durable connection.
What is a bridle joint?
Answer: A bridle joint is a type of joint used in woodworking to join two pieces of material together at right angles, where one piece is notched and the other piece is slotted into the notch.
What is a miter joint?
Answer: A miter joint is a type of joint used in woodworking to join two pieces of material at a 45-degree angle, creating a clean and tight connection.
What is a tongue and fork joint?
Answer: A tongue and fork joint is a type of joint used in woodworking to join two pieces of material end-to-end, where one piece is cut with a projecting tongue and the other piece is cut with a corresponding slot (or fork) to receive the tongue.
What is a lap dovetail joint?
Answer: A lap dovetail joint is a type of joint used in woodworking to join two pieces of material together with interlocking angled fingers (like a dovetail joint), but with one piece overlapping the other to create a stronger connection.
What is a dado joint?
Answer: A dado joint is a type of joint used in woodworking to join two pieces of material together by creating a rectangular groove (the dado) in one piece and fitting the other piece into the groove.
What is a rabbet joint?
Answer: A rabbet joint is a type of joint used in woodworking to join two pieces of material together by creating a rectangular notch (the rabbet) in one piece that the other piece fits into.
What is a butt and rabbet joint?
Answer: A butt and rabbet joint is a type of joint used in woodworking to join two pieces of material together by joining them end-to-end (the butt joint) and creating a rectangular notch (the rabbet) in one piece that the other piece fits into.
What is a dovetail half-blind joint?
Answer: A dovetail half-blind joint is a type of joint used in woodworking to join two pieces of material together with interlocking angled fingers (like a dovetail joint), but with the fingers only visible on one side to create a neater appearance.
What is a lap joint with dowels?
Answer: A lap joint with dowels is a type of joint used in woodworking to join two pieces of material by overlapping them and drilling matching holes for dowels (cylindrical pieces of wood or metal) that are inserted into both pieces to create a strong and durable connection.
What is a pocket screw joint?
Answer: A pocket screw joint is a type of joint used in woodworking to join two pieces of material together at an angle, where a special drill bit creates a pocket hole in one piece, and a screw is driven through the hole and into the other piece, creating a strong and durable connection.
