1.4 Forming, Redistribution And Addition Processes

Question 1

What is bending?

Answer 1

The stamped out net is places onto a folding table, some die cutting presses might be equipped with moving parts that help to bend or fold the net.
For example, when making boxes, the die cut net is held firmly while the sides of the box are bent up along the crease liner

Question 2

Laser cutting

Answer 2

laser cutting can be used to cut, engrave and carve materials like processed paper, cardboard, corrugated card and polymer film.
They are becoming increasingly popular as they are quick, accurate as well as having a a high level of detail.

Question 3

Process of vacuum forming

Answer 3

1. Mole is pressed on the bad of the machine, which is called the ‘platen’
2. Then a polymer sheet is clamped over the mould and a heater is pulled over
3. When the sheet has softened, the platen is raised into the heated polymer and the heat is then removed
4. The vacuum pump is switched on, which sucks the polymer onto the mould
5. Once the polymer has cooled, the platen is lowered and the vacuum is switched off
6. The mould is removed from the moulding, excess polymer is then trimmed off

Question 4

Line bending

Answer 4

This process is used to produce bends in sheets on thermoplastics such as acrylic. This uses an electrically heated element that provides heat along a line. Line bending is used to make acrylic boxes, shelves or point of sales display.

Question 5

Calendaring

Answer 5

This is the smoothing and rolling process used towards the end of the manufacturing of paper. It works by heating pellets of thermoplastic so that it melts into a dough-like consistency. It’s then extruded between a series of heated rollers so that it becomes squashed and stretched to make it thinner. It’s then fished on cooling rollers, which then gets chopping into standard stock sheet sizes.

Question 6

Blow moulding

Answer 6

1. The polymer is fed into the hopper
2. An Archimedean screw pulls the polymer throught he heated section, which melts the polymer
3. The melted polymer is extruded as a tube, which is called a ‘parison’
4. The mould sides close around the parison and air is injected into the mould
5. The polymer is allowed to cool for a few seconds, the mould opens and the finished bottle is ejected

Used to produce mainly: bottles and hollow products

Question 7

Injection moulding

Answer 7

1. Thermoplastic graduals are poured into a hopper
2. A screw threat is rotated by a motor, which pulls graduals thought the chamber
3. The heater melts the polymers
4. When a sufficient amount of polymers have melted and formed at the end of the screw. This injects the polymers into the mould
5. The mould is water cooled, which enables the molten polymer to harden quickly
6. The mould opens and ejector pins push the moulding out
7. Any excess polymers are trimmed off

Uses for the casting of electrical products like computers

Question 8

Extrusion

Answer 8

1. Polymer graduals are loaded into the hopper
   The Archimedean screw moves the polymer granules past heaters
2. The heaters softens the polymer
3. When a goof amount of the polymer is melted, the hydraulic ram pushes the Archimedean screw, forces the polymer through a s tell die
4. The shape of the die determines the shape of the extrusion
5. The extrusion may be supported by rollers as it leaves the die and is cooled by water or air
6. The extrusion is then cut to the desired length

Used to produce either a solid rod, hollow tube like PVC for insulation