1.4 Metal Processes Flashcards
What is press forming?
Press forming shapes sheet metal into 3-D forms.
Metals such as low carbon steel and aluminium are mainly used .
Common in mass production or large scale, batch production, due to set up cost
Dies or mood from hardened tool steel, spark, eroded, and hand burnished to give high-quality surface finish.
What is spinning?
Spinning is a way of forming sheet metal giving radial symmetry.
Often such as kettles and saucepans are made this way .
Spoon products can be identified by parallel lines on the surface
Typically, used in maths and batch production
What is cupping and the drawing?
Coping in deep drawing, are used to form to be like shapes from metal sheets.
Objects such as fire, extinguishers an aerosol cans made this way .
Drawing as when the depth of the pressing exceeds the diameter .
Corners of the punch around it, so the metal scratches instead of shearing.
High set up costs
What is drop forging?
Drop forging is used to shape hot metal
This process is used in the product needs to be tough and hard
Objects such as spanners, pliers and screwdrivers chefs I made this way
Hot metal is forced into shape under great pressure, therefore retain in the original grain structure
This process is suitable for mass production
What is wrought iron forging?
Wrought iron has a very low carbon content making it malleable and easy to shape
They can be used for hand tools, such as hammers
Suitable for one off limited batch production
What is bending?
Press brake is used for bending sheets or plates metal
The stock materials kilometre between a punch in a die
A break holds the metal and lows the punch to Ben the metal into shape
What is rolling?
Rolling is used to reduce the thickness of metals
Typically, used to make structural steals such as beams or bars
Rolling is usually carried out with hot metal that has been heated above recrystallisation temperature
Hot, rolling can result in surface carbon deposits
Metal can be cold road which gives a fine tolerance
What is die casting?
Die, casting is used with lower melting point metals, such as aluminium, pewter and zinc
Two steel is used for the reusable dies
The complexity and cost of making dies, makes it most suitable for mass production
Diecasting producers, a high quality finish
Items include alloy wheels, metal toys and engine components
What is sandcasting?
Sandcasting is used to form high, melting point metals
Carried out in boundaries using mode is made using special greensand
It is a slow and labour-intensive process and moulds are single use only
Used for engine blocks postbox’s and train wheels
What is pewter casting?
Pewter has a low melting point, and is often used in school based casting projects
It is ideal for making jewellery and decorative components
Is suitable for one off production
