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DT - Technical Principles > 16. Metal processes > Flashcards

16. Metal processes Flashcards

1
Q

What can metal processes be grouped into?

A
  • forming
  • redistribution
  • wastage
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2
Q

What are metal forming processes?

A

processes in which no material is removed , but materials are deformed to produce required shapes

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3
Q

What are metal redistribution processes?

A

processes where the metal is changed from one form to another without loss of material
e.g. liquid metal poured into a mould to take a solid shape

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4
Q

What are metal wastage processes?

A

processes that cut away material to leave the desired shape

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5
Q

What are the metal processes?

A
  • press forming
  • spinning
  • cupping and deep drawing
  • drop forging
  • wrought iron forging
  • bending
  • rolling
  • sand casting
  • gravity die casting
  • pressure die casting (hot chamber)
  • pressure die casting (cold chamber)
  • investment casting
  • low temperature pewter casting
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6
Q

What type of process is press forming?

A

forming

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7
Q

What is the metal stock form used for press forming?

A

sheet

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8
Q

What are the key features of press forming?

A
  • shapes sheet metal into 3D forms
  • often used in conjunction with robots for lifting the sheet into place
  • suitable for mass production or large scale batch production
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9
Q

What products are made by press forming?

A
  • metal seats
  • car body panels
  • boxes and containers
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10
Q

Draw the process diagram for press forming, with labels.

A

See flashcards with pic on.

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11
Q

What type of process is spinning?

A

forming

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12
Q

What is the metal stock form used for spinning?

A

sheet

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13
Q

What are the key features of spinning?

A
  • product may show parallel lines where the sheet has been forced onto the mandrel
  • suitable for mass production or small batch production
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14
Q

What products are made by spinning?

A
  • body of stainless steel kettles
  • saucepans
  • metal light shades
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15
Q

Draw the process diagram for spinning, with labels.

A

See flashcards with pic on.

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16
Q

What type of process is cupping and deep drawing?

A

forming

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17
Q

What is the metal stock form used for cupping and deep drawing?

A

sheet (round blank)

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18
Q

What are the key features of cupping and deep drawing?

A
  • starts with metal blank
  • metal is stretched into shape
  • high initial tooling costs
  • used for large scale mass or continuous production
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19
Q

What products are made by cupping and deep drawing?

A
  • tube-like shapes such as fire extinguishers, aerosol cans, drinks cans
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20
Q

Draw the process diagram for cupping and deep drawing, with labels.

A

See flashcards with pic on.

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21
Q

What type of process is drop forging?

A

forming

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22
Q

What is the metal stock form used for drop forging?

A

billet

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23
Q

What are the key features of drop forging?

A
  • used for products that need to be tough and hard
  • maintains the internal grain structure which retains the strength
  • hot metal billet shaped on an anvil or die and then pressed into shape and cooled
  • suitable for mass production
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24
Q

What products are made by drop forging?

A
  • spanners
  • pliers
  • screwdriver shafts
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25
Q

Draw the process diagram for drop forging, with lables.

A

See flashcards with pic on.

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26
Q

What type of process is wrought iron forging?

A

forming

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27
Q

What is the metal stock form used for wrought iron forging?

A

bar

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28
Q

What are the key features of wrought iron forging?

A
  • uses wrought iron (carbon content less than 0.08%)
  • can be hand or hydraulic press process
  • suitable for one off or small batch production
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29
Q

What products are made by wrought iron forging?

A
  • decorative metalwork such as gate scrolls
  • decorative fencing
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30
Q

Draw the process diagram for wrought iron forging, with labels.

A

See flashcards with pic on.

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31
Q

What type of process is bending?

A

forming

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32
Q

What is the stock form used for bending?

A

sheet or plate

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33
Q

What are the key features of bending?

A
  • does not include any punching or trimming of the metal
  • simple bending can be carried out in a school or college workshop
  • used for large scale batches in industry
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34
Q

What products are made by bending?

A
  • seams on metal edges
  • bending sheets for product casings or housings
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35
Q

Draw the process diagram for bending, with labels.

A

See flashcards with pic on.

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36
Q

What type of process is rolling?

A

forming

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37
Q

What is the stock form used for rolling?

A

billet

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38
Q

What are the key features of rolling?

A
  • hot rolling metal results in uniform mechanical properties, no deformation or stresses
  • surface usually coated with carbon deposits, which must be removed using acid picking
  • cold rolling results in a material that has tighter tolerance and better surface finish
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39
Q

What products are made using rolling?

A
  • hot rolling
    • I beams
    • angle bar
    • plate and channel
    • railway tracks
  • cold rolling
    • filing cabinets
    • chairs
    • steel drums
    • containers
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40
Q

Draw the process diagram for rolling, with labels.

A

See flashcards with pic on.

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41
Q

What type of process is sand casting?

A

redistribution

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42
Q

What is the stock form used for sand casting?

A

molten metal from a billet

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43
Q

What are the key features of sand casting?

A
  • labour intensive process
  • not a high quality surface finish
  • suitable for one off or small batch production
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44
Q

What products are made by sand casting?

A
  • railway carriage wheels
  • wood working clamps
  • vices
  • motor housings
  • bollards
  • drain covers
  • post boxes
45
Q

Draw the process diagram for sand casting, with labels.

A

See flashcards with pic on.

46
Q

What type of process is gravity die casting?

A

redistribution

47
Q

What is the stock form used for gravity die casting?

A

molten metal from a billet

48
Q

What are the key features of gravity die casting?

A
  • lower melt point metals such as aluminium, aluminium alloys and zinc based alloys
  • relies on gravity to help the metal flow into the mould
  • used for thicker mould sections
  • used for very large batch and mass production
49
Q

What products are made by gravity die casting?

A
  • allow wheels
  • engine components
  • door knobs and handles
50
Q

Draw the process diagram for gravity die casting, with labels.

A

See flashcards with pic on.

51
Q

What type of process is pressure die casting (hot chamber)?

A

redistribution

52
Q

What is the stock form used for pressure die casting (hot chamber)?

A

molten metal from a billet

53
Q

What are the key features of pressure die casting (hot chamber)?

A
  • lower melt point metals such as aluminium, aluminium alloys and zinc based alloys
  • molten metal stored in a chamber then a shot of molten metal is forced into the die
  • fast process
  • used for very large batch and mass production
54
Q

What products are made by pressure die casting (hot chamber)?

A
  • toy cars
  • collectible figures
  • decorative door knobs and handles
55
Q

Draw the process diagram for pressure die casting (hot chamber), with labels.

A

See flashcards with pic on.

56
Q

What type of process is pressure die casting (cold chamber)?

A

redistribution

57
Q

What is the stock form used for pressure die casting (cold chamber)?

A

molten metal from a billet

58
Q

What are the key features of pressure die casting (cold chamber)?

A
  • lower melt point metals such as aluminium, aluminium alloys and zinc based alloys
  • molten metal ladled into the shot chamber and hydraulically pushed into the chamber
  • used for very large batch and mass production
59
Q

What products are made by pressure die casting (cold chamber)?

A
  • toy cars
  • collectible figures
  • decorative door knobs and handles
60
Q

Draw the process diagram for pressure die casting (cold chamber), with labels.

A

See flashcards with pic on.

61
Q

What type of process is investment casting?

A

redistribution

62
Q

What is the stock form for investment casting?

A

molten metal from a billet

63
Q

What are the key features of investment casting?

A
  • used for intricate or awkward shapes that would be difficult or impossible to mould using any other casting process
  • high quality excellent finish
  • wax patterns are cast from a master mould
  • repeatable, quality process
64
Q

What products are made by investment casting?

A
  • cast jewellery
  • collectible figures
  • hip replacement joints
65
Q

What type of process is low temperature pewter casting?

A

redistribution

66
Q

What is the stock form used for low temperature pewter casting?

A

molten metal from a billet

67
Q

What are the key features of low temperature pewter casting?

A
  • used for school or college projects
  • can be used with simple MDF moulds
  • suitable for one off production or small batch (with aluminium moulds)
68
Q

What products are made by low temperature pewter casting?

A
  • jewellery
  • key fobs
  • decorative components
69
Q

What are the addition/fabrication processes?

A
  • MIG welding
  • TIG welding
  • oxy-acetylene welding
  • spot welding
  • soldering
  • brazing (hard soldering)
  • riveting and pop riveting
70
Q

What type of process is MIG welding?

A

addition

71
Q

What are the key features of MIG welding?

A
  • uses an electrode wire
  • suitable for thin-gauge metals, medium carbon steel or aluminium
  • uses an inert gas such as CO2 or argon
  • suitable for one off fabrication or on an assembly line
72
Q

What products are made by using MIG welding?

A
  • tubular produts
    • climbing frames
    • bike frames
    • vehicle exhausts
73
Q

Draw the process diagram for MIG welding, with labels.

A

See flashcards with pic on.

74
Q

What type of process it TIG welding?

A

addition

75
Q

What are the key features of TIG welding?

A
  • uses a filler rod
  • accurate, strong welds but requires high skill
  • slow method
  • uses an inert gas (argon or helium)
76
Q

What products are made by using TIG welding?

A

– stainless steel ladders for boats or swimming pools
- welding stainless steel car exhausts

77
Q

Draw the process diagram for TIG welding, with labels.

A

See flashcards with pic on.

78
Q

What type of process is oxy-acetylene welding?

A

addition

79
Q

What are the key features of oxy-acetylene welding?

A
  • uses a steel filler rod
  • useful for quick repair jobs or in remote locations where there is no electric power supply
80
Q

What products are made by using oxy-acetylene welding?

A

used to weld mild steel sheet, tube or plate where arc welding processes are not available

81
Q

Draw the process diagram for oxy-acetylene welding, with labels.

A

See flashcards with pic on.

82
Q

What type of process is spot welding?

A

addition

83
Q

What are the key features of spot welding?

A

sheet held between two copper electrodes that form a weld when the charged electrodes make contact with the metal

84
Q

What products are made by using spot welding?

A
  • used to weld mild steel sheet metal at points along a length
85
Q

What type of process is soldering?

A

addition

86
Q

What are the key features of soldering?

A
  • uses a filler material of a lower melting point than the metal being joined
  • typically solders are an alloy of tin and copper
87
Q

What products are made by soldering?

A
  • lightweight applications
  • thin gauge metals
  • joining precious metals such as gold and silver
  • for jewellery
  • joining copper pipe in plumbing
88
Q

What type of process of brazing (hard soldering)?

A

addition

89
Q

What are the key features of brazing?

A
  • uses a brass filler rod
  • carried out using either oxy-acetylene or a gas and compressed air brazing hearth
  • suitable for one off production or small batch
  • used to join dissimilar metals such as mild steel sheet to aluminium, copper and nickel
90
Q

What products are made by brazing?

A
  • lower temperature than welding, so suitable for joining thinner gauge mild steel tude or bar
91
Q

What type of processes are riveting and pop riveting?

A

addition

92
Q

What are the key features of riveting?

A
  • uses two pieces that are overlapped and drilled
  • the end of the shaft is then hammered over to join
93
Q

What are the key features of pop riveting?

A
  • uses a rivet gun (or riveting pliers) and a rivet and pin
  • good for where underside of joint is inaccessible
94
Q

What products are made by using riveting and/or pop riveting?

A

sheet metal or plate joining

95
Q

Draw the process diagram for riveting, with labels.

A

See flashcard with pic on.

96
Q

Draw the process diagram for pop riveting, with labels.

A

See flashcard with pic on.

97
Q

What are the temporary fasteners and joining methods?

A
  • self-tapping screws
  • machine screws
  • nut and bolt
98
Q

When are temporary fasteners used?

A
  • where a permanent joining method is not required
  • in situations where a product may need to be disassembled or accessed for repair
99
Q

What are self-tapping screws?

A
  • used for joining thin sheet metal
  • pilot hole is drilled through the metal parts to be joined
  • as the screw is screwed in, it cuts its own thread, which holds the screw in place
100
Q

What are machine screws?

A
  • a type of bolt where the thread is the whole length of the shaft
  • used to join thicker pieces of metal such as inspection covers on motor or gear housings
  • top part to be joined will have a clearance hole larger than the thread on the bolt
  • the bolt goes through this and is screwed into a threaded hole in the second piece
  • machine screws are often tightened with a spanner or Allen key
101
Q

What are nut and bolts?

A
  • bolts are similar to machine screws, but instead of being inserted into a threaded hole, the go all the way through both pieces of metal
  • a nut is tightened on to the end to keep the pieces together
102
Q

What are the metal wasting processes?

A
  • milling
  • turning
  • flame cutting
  • plasma cutting
  • laser cutting
  • punching/stamping
103
Q

What is milling?

A
  • the work to be machined is clamped on to the table of the machine
  • the table can run in the x direction (left and right horizontally), the y direction (forwards and backwards), and the z direction (up and down vertically)
  • to cut slots, shape edges or thread holes
104
Q

What is turning?

A
  • carried out on a centre lathe
  • work such as a bar can be held in a rotating chuck and machined to reduce the diameter, and to square or ‘face-off’ the end, thread and drill
  • can be done manually or by using CNC lathes
  • material is machined by cutting tools held in place in a tool post, which can be moved in and out, and along the bar
105
Q

What is flame cutting?

A
  • uses oxy-acetylene gas and a special flame cutting torch to deliver a very intense and focused flame above 3500 degrees
  • used to cut low carbon and alloy steel plate
  • has an additional jet of oxygen to intensify the flame and pierce the metal
  • does not require electricity
  • disadvantage is that it is difficult to maintain a parallel line with high levels of tolerance
106
Q

What is plasma cutting?

A
  • plasma is a super-heated ionised gas that is electrically conductive
  • plasma cutter will use this to transfer the energy from the power supply to a conductive material such as steel plate
  • the heat generated by the plasma can be as high as 28,000 degrees, which quickly burns through the material and blows it away
  • the resulting cut is fast and clean
107
Q

What is laser cutting?

A
  • process can be used in industry for precision cutting metals
  • lower-powered lasers are readily available in schools and colleges to cut manufactured boards and acrylic sheet
  • uses the power from a high powered laser beam that is directed through optics
  • the laser head contains a lens that focuses the laser into a fine beam for cutting and engraving
  • usually have a very fine tolerance
  • laser cutting is more accurate and uses less energy than plasma cutting, but cannot cut the same thickness of material
  • in industry, laser cutting is typically used to cut flat sheet material, but not able to cut the same thickness as plasma cutting
108
Q

What is punching/stamping?

A
  • uses computer controlled machines that stamp out sections of sheet material
  • uses the shearing action on a sheet metal placed between an upper tool (punch) and lower tool (die)
  • suitable for small and medium size production runs
  • normally used for processing materials from 0.5mm to 6mm thickness

DT - Technical Principles (29 decks)

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