16-Metal Processes Flashcards
1
Q
What are the three types of metal processes?
A
- Forming
- Redistribution
- Wasting
2
Q
Metal Processes - Press Forming
A
- Metal sheet placed over die
- Press will be lowered to form the sheet to the die
3
Q
Metal Processes - Spinning
A
- Used to form sheet metal into round objects such as a kettle
- Sheet metal is spun while rollers push the sheet metal to form around the shape of the mandrel
4
Q
Metal Processes - Cupping and Deep Drawing
A
- Forms Tube shaped shapes for example a fire extinguisher
- Uses metal blank stock form
- This is held over a cavity and pressed down by a deep drawing punch to form the shape
5
Q
Metal Processes - Drop Forging
A
- A lower die placed on top of an anvil and an upper die on the end of the Ram
- A heated metal billet will be placed onto the lower die, it will be heated to just above its recrystallisation temperature
- Ram will lower onto the billet to form the metal to the desired shape
- Makes products like spanners
6
Q
Metal Processes - Wrought Iron Forging
A
- Metal is heated and then hammered, bent, and rolled into its correct shape
- Only works for Iron with a carbon content of less than 0.08%
- Will usually use a bar stock form
7
Q
Metal Processes - Bending
A
- Sheet metal placed over a V shaped die
- Punch will then lower to push the sheet metal into the V forming an edge
8
Q
Metal Processes - Rolling
A
- Thicker metal will go through rollers which will compact and thin out the metal
- This can be done hot or cold
9
Q
Metal Processes - Sand Casting
A
- Mould created in sand
- Molten metal will be poured into the mould and left to cool
- Used on metals with high melting points
- Labour intensive and doesn’t produce a high quality finish on the metal
10
Q
Metal Processes - Die Casting
A
- Molten metal from a billet is poured into a die
- This will usually rely on gravity for the metal to take the shape
- Used with metals with lower melting point like aluminium
- Often used to make door knobs
10
Q
Metal Processes - Investment casting
A
- exact replica of model is made in wax
- This is then submerged in refectory clay, and placed in a kiln
- This melts the wax, leaving a perfect mould within the clay
- Molten metal is then poured into the mould and left to cool
- This is mainly used for intricate designs like jewellery
11
Q
Metal Processes - Low Temperature Casting (Pewter)
A
- Two piece mould made out of MDF usually will be clamped together
- Molten pewter then poured into the mould and left to dry
- Used mainly in schools for one off production
- Used to make small decorative items